Kersten HyCut User manual

Original operating
instructions
HyCut.
Order:
from Masch.-Nr.: Rev.: R01 As of: 2021-01-27

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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 reproduced, distributed or
otherwise made publicly available without prior written consent and except in cases permitted by law.
Changes without prior notice are reserved. The original document has been published in German. All
translations are copies of the original document.
Copyright 2021 at Kersten Arealmaschinen GmbH
Kersten Arealmaschinen GmbH
Empeler Straße 95
46459 Rees
Germany
Phone: [phone]
Fax: [phone]
[e-mail]
http://www.kersten-maschinen.de/

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Information on the operating instructions
This guide makes it possible to use the machine safely and efficiently. The manual
is part of the machine and must be kept accessible to the personnel at all times in
the immediate vicinity of the machine.
Staff must have carefully read and understood this manual before starting all work.
The basic requirement for safe working is compliance with all the safety
instructions and instructions given in this manual.
Risk of accident and damage to property if used improperly!
Since self-propelled equipment emanates significant sources of accident or danger
when not used properly, it is imperative to provide instruction to competent and
authorised persons during the initial commissioning of the Kersten work equipment.
The best way to familiarize yourself with its basic functions and its handling is to
choose a free and level terrain for your first trip.
• For further information and in case of difficulties of any kind, please contact
the dealer, importer or directly the manufacturer.
• Share all security instructions with other users!
In addition, local health and safety regulations and general safety regulations apply
to the field of use of the machine.
Co-existing documents
In addition to this manual, the following documents and the safety instructions
listed there in it must be observed:
• Operating instructions of the radio remote control
• Operating instructions of the internal combustion engine
Manufacturer's Customer Service
For technical information, please contact the machine manufacturer's customer
service:
Manufacturer's address
Kersten Arealmaschinen GmbH
Empeler Straße 95
46459 Rees
Germany
Service telephone + 49 2851 9234-10
Fax + 49 2851 9234-44
E‑mail
[e-mail]
Internet http://www.kersten-maschinen.de
In case of enquiries, please provide the following information:
• Machine/device type
• Machine order number
• In case of problems: exact description or exact error messages

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1 Foreword
2 Safety
2.1 Symbols in this guide ....................................................................................................................7
2.2 Pictograms ..................................................................................................................................9
2.3 Appropriate use............................................................................................................................11
2.4 Working and hazardous areas .......................................................................................................12
2.5 Safety during the work process ......................................................................................................13
2.6 Mowing on the slope.....................................................................................................................14
2.7 Safety devices .............................................................................................................................16
2.7.1 Emergency shutdown via emergency stop switch ........................................................................16
2.8 Safety marking .............................................................................................................................17
2.9 Remaining Hazards ......................................................................................................................17
2.10 Environmental Protection.............................................................................................................20
3 Functional description 22
3.1 Overview.....................................................................................................................................22
4 Transport, packaging and storage 25
4.1Safety instructions .........................................................................................................................25
4.2 Transport inspection .....................................................................................................................25
4.3 Packaging ...................................................................................................................................25
4.4 Transport of the machine...............................................................................................................26
4.5 Towing …………….........................................................................................................................28
5 Assembly/installation, installation, initial commissioning 29
5.1 Safety instructions ........................................................................................................................29
6 Operation 30
6.1 Safety instructions ........................................................................................................................30
6.2 Wireless remote control .................................................................................................................30
6.3 Switching the mower ....................................................................................................................34
6.4 Driving / Switching on ...................................................................................................................35
6.5 Switching mowers ........................................................................................................................36
7 Maintenance 38
7.1 Safety instructions ........................................................................................................................38
7.2 Spare parts..................................................................................................................................38
7.3 Maintenance ................................................................................................................................38
7.3.1 Checking safety devices for function...........................................................................................38
7.3.2 Daily Exam...............................................................................................................................39
7.3.3 Maintenance after 20 operating hours / longer downtime ..............................................................40
7.3.4 Maintenance after 100 operating hours / longer downtime.............................................................41
7.4 Knife change of mower..................................................................................................................42
7.4.1 Swap plates with all knives attached to them...............................................................................43
7.4.2 Swapping opposite knives.........................................................................................................44
7.5 Clean air filter...............................................................................................................................45
7.6 Chain pulling................................................................................................................................46

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7.7Setting chain voltage ....................................................................................................................48
7.8 Charging batteries .......................................................................................................................50
7.8.1 Charger with 48 volts...............................................................................................................51
7.8.2 Charger with 24 volts...............................................................................................................52
7.8.3 Charger with 12 volts................................................................................................................53
7.9 Cleaning machine.........................................................................................................................54
7.10 Measures after maintenance ........................................................................................................54
7.11 Storage .....................................................................................................................................55
8 Faults / Troubleshooting 56
8.1 Safety instructions ........................................................................................................................56
8.2 Warning codes .............................................................................................................................56
8.3 Cause of fault and its remediation...................................................................................................56
8.4 Fault Table Petrol Engine .............................................................................................................56
8.5 Fault table control........................................................................................................................58
8.6 Fault table drive ..........................................................................................................................58
8.7 Fault table Mower drive ................................................................................................................59
9 Disassembly, disposal 60
9.1 Safety instructions ........................................................................................................................60
9.2 Dismantling .................................................................................................................................60
9.3 Disposal ......................................................................................................................................60
10 Technical data 62
10.1 General .....................................................................................................................................62
10.2 Electric motors / batteries ............................................................................................................62
10.3 Radio Remote Control.................................................................................................................63
10.4 Motortype ..................................................................................................................................63
10.5 Declaration of Conformity ............................................................................................................64

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1 Preface
Dear customer,
Thank you for choosing a quality product from Kersten.
This product has been manufactured according to state-of-the-art manufacturing
processes and extensive quality assurance measures, because only when you are
satisfied with your equipment is our goal achieved.
Before using this machine or attachment for the first time, please read these
operating instructions in full and conscientiously.
If you do not understand any information in this safety data sheet or the product-
specific assembly or operating instructions, please contact your seller or the
machine manufacturer directly.
Keep these operating instructions at your fingertips. You can then read important
information and instructions if necessary.
Enjoy your kersten device
Dipl.- Ing. (FH) Robert Bosch
Managing director

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2 Security
2.1 Symbols in this guide
Safety
The following occupational safety symbols are indicated by all safety indications
which indicate a danger to the life and limb of persons and are indicated by a
pictogram, a signal word and a signal colour.
In the documentation you will find the danger situations explained at the relevant
places.
Observe these notes!
Observe the local safety and accident prevention regulations!
Risk
Type and source of danger
This symbol warns of an immediate danger to the life and health of individuals.
Failure to heed these instructions leads to serious health effects, as well as life-
threatening injuries and extensive property damage.
• Action that must be omitted to prevent the danger from occurring
Warning
Type and source of danger
This symbol warns of an imminent danger to the life and health of persons, as
well as environmental and property damage.
Failure to heed these instructions can lead to serious health effects, as well as
life-threatening injuries, or cause extensive environmental and property damage.
• Action that must be omitted to prevent the danger from occurring
Caution
Type and source of danger
This symbol warns of an imminent danger to the health of persons as well as
environmental and property damage.
Failure to observe these instructions can have moderate or mild health effects up
to injury or lead to extensive environmental and property damage.
• Action that must be omitted to prevent the danger from occurring
Note
Type and source of machine or plant damage
This symbol warns of a dangerous situation and is used to identify a reference to
how to handle the machine or system.
Failure to observe these instructions may result in extensive damage to property.

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• Action that must be omitted so that the damage to the machine or plant
does not occur
Tips and recommendations
This symbol highlights useful tips and recommendations, as well as information
for efficient and trouble-free operation.
Other markings
To highlight instructions, results, listings, references, and other elements, this
guide uses the following tags:
Marking
Explanation
1., 2., 3. ... Step-by-step instructions

Results of action steps
• Collections without a set order
[Button] Controls (e.g., buttons, switches), display elements (e.g.,
signal lights)
"Advertisement"
Screen elements (e.g., buttons, assignment of function
keys)

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2.2 Pictograms
Observe instructions
Do not use the flagged machine until the manual has been read.
Wear health and safety clothing
This sign indicates that protective clothing must be worn in the area concerned.
Workwear is tight-fitting work wear with low tear resistance, with tight sleeves and
no protruding parts.
Wear safety shoes
This sign indicates that safety shoes must be worn in the area concerned.
Safety shoes protect the feet from crushing, falling parts and sliding out on slippery
surfaces.
Wear protective gloves
This sign indicates that protective gloves must be worn in the area concerned.
Protective gloves are used to protect the hands from friction, abrasions, punctures,
cuts or deeper injuries as well as against contact with hot surfaces.
Wear protective goggles
This sign indicates that protective goggles must be worn in the area concerned.
The goggles are used to protect the eyes from flying parts and liquid splashes.

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Operating instructions and safety instructions
Before commissioning, read and observe the operating instructions and
safety instructions.
Never open or remove protective devices when the motor is running.
Observe the notes in the technical manual.
Lubrication point!
only touch machine parts when they have come to a complete standstill.
Danger from dispersing parts when the engine is running.
Keep a safety distance!

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2.3 Appropriate use
Warning
Risk of injury / risk of environmental damage due to improper use of the
machine!
Due to improper use of the machine there is a risk of injury, as well as danger for
environmental and property damage (on the machine or plant)!
• The HyCut mower is built for the usual or common mowing applications in
agriculture and forestry, such as .B green space and plant maintenance.
• Any further use is deemed not to be intended. The manufacturer is not
liable for any resulting damages, the risk for this is borne solely by the
operator.
• The intended use includes compliance with the operating, maintenance
and maintenance conditions prescribed by the manufacturer.
• HyCut mowers may only be used, maintained and repaired by persons who
are familiar with it and are aware of the dangers.
• The relevant accident prevention regulations as well as other generally
accepted safety and occupational health regulations must be complied
with.
• Unauthorized changes to the machine lead to the manufacturer's exclusion
of liability for the resulting damages.
2.4 Areas of work and danger
Fig. : Danger area (top view)1
1 ejection range of the cutting unit,max. 10 m

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2 HyCut Mower
• RED danger area (stay prohibited / prohibited)
• GREEN working area (the entire surface to be machined)
Warning
Risk of injury / danger of environmental damage due to working / stopping
in the danger zone!
Due to the work / stopping in the danger zone there is a risk of injury, as well as
danger for environmental and property damage (on the machine or plant)!
• The user is responsible to third parties in the danger zone of the machine!
• Staying in the danger zone of the machine is prohibited! Refer to all
people from the danger zone.
• When people approach the danger zone, the machine must be parked.
• The operator must take care that there are no persons or tangible assets in the
possible ejection area.
• Before switching on the mower and starting up, check the danger area.
Particular attention must be paid to children and animals. Pay attention to
sufficient visibility!
• Turn off the machine in areas that are difficult to see and make sure that
no one is in the danger zone.
• Before starting work, foreign objects must be removed from the surface to be
processed. Pay attention to other foreign bodies at work and remove them
in good time.
• In the case of work in the immediate vicinity of public roads and paths, care
must be taken to ensure that the ejection area of the mower can be in the
working area and that there is therefore a risk of injury to third parties.
• In the case of work on public roads and squares or in the immediate
vicinity, signs and hazard signs must be put up to draw the attention of
third parties.
2.5 Safety during the work process
Warning
Risk of injury / risk of environmental damage due to non-compliance with
safety measures!
Failure to comply with the safety measures poses a risk of injury, as well as a risk
of environmental and material damage (to the machine)!
• Never leave the HyCut mower unattended while driving.
• In addition to the instructions in this manual, observe the general
applicable safety and accident prevention regulations!
• HyCut mower must not be operated by persons under the age of 16, even
under the supervision of an adult! Children and adolescents must be
instructed not to play with the device.
• Only trained personnel or persons are allowed to use this machine!
• When using public transport routes, observe the relevant regulations!

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• HyCut is not approved for public transport.
• The user's clothing should be tight. Avoid loosely worn clothing and wear
sturdy footwear or safety shoes!
• Work only in good visibility and light conditions!
• The attached warning and warning signs give important information for
safe operation; attention is paid to your safety!
• For transport on motor vehicles or trailers outside the area to be machined,
the engine must be switched off!
• Be careful with rotating mulch knives - safety distance!
• Be careful with trailing mulch knives. Wait until they stand still before
working on them!
• If the mulch knives are blocked by a foreign body, the emergency stop
switch must be operated immediately. Before cleaning the mower with a
suitable aid, the mower must be switched off by moving and pulling off the
circuit breaker!
• There are crushing and squeezing parts on driven parts!
• The transport of persons and objects is prohibited!
• Driving behaviour, steering and, if necessary, braking ability as well as
tilting behaviour are influenced by the corresponding terrain contour / slope
position. The working speed must be adjusted to the respective conditions.
• Unauthorized modifications that endanger the operational safety of the
machine are prohibited!
• In case of damage to the mower, the emergency stop switch must be
operated immediately. Before repairing the damage, the mower must be
switched off by moving and pulling off the circuit breaker!
• For work on a slope, the accompanying person above the vehicle must be
at a sufficient distance from the HyCut mower! For the operator, it is
recommended to wear crampons if necessary.
• If possible, always drive across the slope.
• Do not operate the machine in humidity and rain in the slope.
• In case of malfunction on the steering, stop the HyCut mower and turn off
the motor immediately. Eliminate the fault immediately.
• Before each commissioning, check the machine for operational safety!
• If the HyCut mower starts to slide in the slope, the emergency stop switch
of the remote control must be immediately released.

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2.6 Mowing on the slope
Fig. : Mowing on the slope2
1 position above the slope above the mowing caterpillar
2 Position above the slope offset to the mowing caterpillar
3 Position in the slope
4 Position below the slope offset to the mowing caterpillar
5 Position below the slope in the fall line of the mower
Above illustrations show the recommended and forbidden positions during the
operation of the mower on the slope.
• In any case, the position below the slope in the fall line of the mower (5) is
prohibited.
• For vertical directions of travel in the slope, the position above the slope
above the mower (1 in the left figure) is also prohibited.
• The position in the slope (3) is marked with a question mark and should
always be avoided as far as possible.
Warning
Risk of injury / risk of environmental damage due to mowing on the slope!
There is a risk of injury as well as damage to the environment and property (on
the machine) due to mowing on a slope!
• Never leave the HyCut mower unattended while driving.
• In addition to the instructions in this manual, observe the general
applicable safety and accident prevention regulations!
• If the HyCut mower starts to slide in the slope, the emergency stop switch
of the remote control must be immediately released.

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2.7 Safety
• The operator must always be aware of the local conditions, in particular the
gradient and adjust his position accordingly. The distances described in
relation to the danger zone must be observed (see Chapter 2.4 Working
and hazardous areas on page 14).
• Do not mow on slopes that are steeper than 50° (120%). Driving on slopes
with a maximum gradient of 50° can only be achieved under optimal
conditions.
• Mowing on wet grass or dry sand should be refrained from doing so.
Depending on the degree of wetness of the grass, the grain of the sand
and the slope, the mower caterpillar begins to slide uncontrollably even
with a low slope. As a rule, the machine can no longer be stopped in such
situations. The uncontrollable slipping must therefore be avoided in any
case.
• Check the area to be mowed for foreign objects.
• Check the terrain to be mowed on steps and holes that could destabilize
the mower.
• Always carefully manoeuvre the mower and drive slowly downhill.
• Mow horizontally in one direction on the slope and reverse the direction of
travel at the end of each row via the lever.
• The speed must be set at the rotary potentiometer of the radio remote
control. This prevents "oversteering" of the driving lever.
• Never leave the mower on a slope with the engine running.
• Never stand below the mower.
• Never drive the mower out of sight. When crossing Kuppen, the mower
must be stopped near the hilltop. Change your position so that you get a
clear view of the other side of the hill.
• Do not suddenly start or stop the mowing caterpillar while going
uphill/downhill. Special care should be taken when changing direction on
the slope.
Risk
Danger of life or injury due to non-functioning safety devices!
In the case of non-functioning or overridden safety devices, there is a risk of
serious injury, even death.
• Before starting work, check that all safety devices are functional and
correctly installed.
• Never override or bridge safety devices.
• Ensure that all safety devices are always accessible.

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2.7.1 Emergency shutdown via emergency stop switch
Fig. : Emergency stop switch3
1 emergency stop switch Mower
2 Emergency Stop Switch Remote Control
There is an emergency stop switch on the top of the mower (1) and an emergency
stop switch on the remote control (2). In the event of an emergency, immediately
press the emergency stop switch of the mower (1) or the remote control (2).
• The HyCut mower remains standing
• The power supply to the motor controllers remains
• The internal combustion engine is switched off
• The knife drive is stopped
The following steps have to be implemented before you start again!
• Eliminate the cause of the error/ hazardous situation.
• Bring emergency stop switch back into output position.
2.8 Safety marking
The following icons and signs are located in the workspace. They refer to the
immediate environment in which they are located.

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Warning
Risk of injury due to illegible or missing signage!
Missing and illegible stickers and signs can have serious health effects and life-
threatening injuries.
• Keep all safety, warning and operating instructions in always easy-to-read
condition.
• Immediately renew damaged signs or stickers.
2.9 Residual hazards
The machine is designed according to the state of the art and according to current
safety requirements. Nevertheless, residual risks remain that require prudent
action. The rest hazards and the resulting behaviours and measures are listed
below.
Improper transport
Note
Damage to property due to improper transport
In case of improper transport, items of transport may fall or overturn. This can
cause material damage in a significant amount.
• Take care when unloading the items during delivery as well as during
internal transport and observe the symbols and instructions on the
packaging.
• Use only the intended stop points.
• Remove packaging just before assembly.
Dirt and objects lying around
Caution
Risk of injury due to falls over dirt and objects lying around!
Dirt and objects lying around form sources of slips and stumbling. Injuries can be
caused in a fall.
• Always keep the working area clean.
• Remove items that are no longer needed from the working area and, in
particular, from the ground.
• Remove tools or parts from the workspace.
Cleaner
Warning
Risk of injury due to improper handling of detergents or substances
Improper handling of detergents or substances can lead to serious health effects
up to life-threatening injuries.

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• Read the material safety data sheets and instructions of the manufacturers
applicable to the cleaning agents or substances
• Wear the appropriate protective equipment (e.B. gloves, safety shoes,
protective suit, breathing mask, goggles, etc.)
• Ensure adequate ventilation of the environment
• Be careful when handling hot detergents or substances. Touching can lead
to burns and scalding
• If necessary, clean parts, assemblies or components of adhering oils,
greases and other dirt
• Avoid skin contact with detergents or fabrics
• Do not inhale vapours from detergents or substances
• Do not handle near open fires and do not smoke
Noise level
Valid noise regulations must be observed as well as the warnings of the overall
documentation. The noise level on site depends on the local ambient noise. The
noise level shall be checked at regular intervals by the operator.
Warning
Risk of injury due to noise!
The noise level occurring in the working area can cause severe hearing damage.
• Covers, insulating materials and other insulating equipment must not be
removed and must be replaced in the event of damage.
• If the daily noise exposure level exceeds 85 dB(A), in this case the wearing of
hearing protection must be ordered from the operator's side.
• Stop in the danger zone only if necessary.

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Moving components
Risk
Danger of life or injury due to moving components!
Due to improper handling of moving components, there is a risk of life or injury as
well as a risk of damage to the machine or plant
• Do not interfere with moving components or handle moving components during
operation.
• Never open covers during operation.
• Observe the follow-up time: before opening the covers, make sure that no
more components are moving.
• Wear tight-fitting workwear with low tear resistance in the hazardous area.
Sharp edges and sharp corners
Caution
Risk of injury due to sharp edges and sharp corners!
Sharp edges and sharp corners can lead to skin abrasions and cuts.
• Be careful when working near sharp edges and sharp corners.
• Wear protective gloves in case of doubt.
Equipment / Operating Materials / Lubricants / Oils
Warning
Risk of injury due to improper handling of equipment or materials!
Improper handling of equipment or substances can lead to serious health effects
up to life-threatening injuries.
• Read the material safety data sheets and instructions of the
manufacturers applicable to the equipment or/substances.
• Wear the appropriate protective equipment (e..B gloves, safety shoes,
protective suit, breathing mask, goggles, etc.).
• After unintentional eye contact, rinse the eyes thoroughly with plenty of
water and consult a doctor.
• Wash thoroughly with plenty of water after skin contact.
• Ensure adequate ventilation of the environment.
• Be careful when handling hot equipment or materials. Touching can lead to
burns and scalding.
• If necessary, clean parts, assemblies or components of adhering oils,
greases and other dirt.
• Avoid skin contact with equipment or substances.
• Do not inhale vapours from equipment or materials.
• Do not handle near open fires and do not smoke.

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2.10 Environmental protection
Warning
Environmental damage hazard due to improper handling of operating
equipment or operating materials as well as cleaning agents or cleaning
agents!
Improper handling of equipment or materials as well as cleaning agents or
substances can result in extensive environmental and material damage.
• Read the material safety data sheets and instructions of the manufacturers
applicable to the equipment or consumables as well as cleaning agents or
cleaning substances
• Store water- and soil-hazardous equipment or consumables, such as oil-
contaminated parts, assemblies or components in secured areas or
collection tanks
• Bind leaked equipment or consumables as well as detergents or cleaning
agents with a binder and dispose of it in accordance with local regulations
• If necessary, clean parts, assemblies or components of adhering oils,
greases and other dirt
• Do not allow leaked equipment or consumables as well as cleaning agents
or cleaning substances to seep into the soil or enter the sewer system
The following hazardous substances are used:
Lubricants
Lubricants such as greases and oils contain toxic substances. They must not enter
the environment. Disposal must be carried out by a specialist waste disposal
company.
Oils
Oils (e.g. lubricating, hydraulic or cleaning oils) must not enter the environment.
Oils lead to long-term adverse effects in water bodies. Disposal must be carried out
by a specialist waste disposal company.
safety data sheets of the manufacturer.
Electronic components
Electronic components may contain toxic substances. They must not enter the
environment. Disposal must be carried out by a specialist waste disposal company.
Batteries and batteries
Batteries and batteries contain toxic heavy metals. They are subject to hazardous
waste treatment and must be handed over to municipal collection points or
disposed of by a specialist company.