Kongskilde FC 860 User manual

ORIGINAL INSTRUCTIONS - according to Directive 2006/42/EC, Annex I 1.7.4.1
Part number 81PIGB-204x
1st edition English
February 2018
FC 860
Harvester
OPERATOR’S MANUAL

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FOREWORD
DEAR CUSTOMER!
We appreciate the confidence you have shown to our company by investing in a
KONGSKILDE product and congratulate you on your new purchase. Of course, it is
our wish that you will experience complete satisfaction with the purchase investment.
This instruction manual contains information about correct and safe use of the
machine.
When buying the machine you will receive information about use, adjustment and
maintenance.
However, this first introduction doesn’t replace a more thorough knowledge of the
different tasks, functions and correct technical use of the machine.
Therefore you should read this instruction manual very carefully before using
the machine. Pay special attention to the safety instructions.
This instruction manual is made so that the information is mentioned in the order you
will need it, i.e. from the necessary operation conditions to use and maintenance.
There are illustrations to support the instructions.
"Right" and "Left" are defined from a position behind the machine facing the direction
of travel.
All the information, illustrations and technical specifications in this instruction manual
describe the latest version at the time of publication.
Kongskilde Industries A/S reserves the right to make changes or improvements in the
design or construction of any part without incurring the obligations to install such
improvements on any unit previously delivered.

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CONTENTS
FOREWORD.......................................................................................................................3
CONTENTS.........................................................................................................................4
1. INTRODUCTION.............................................................................................................6
INTENDED USE.................................................................................................6
PERFORMANCE................................................................................................7
SAFETY..............................................................................................................9
Definitions............................................................................................10
General safety instructions...................................................................11
Locking of guards.................................................................................13
Choice of tractor...................................................................................13
Connection and disconnection.............................................................14
Adjustment...........................................................................................15
Transport..............................................................................................16
Working................................................................................................17
Parking.................................................................................................17
Greasing ..............................................................................................17
Grinding ...............................................................................................18
Maintenance ........................................................................................19
Replacement of wearing parts .............................................................19
Safety decals .......................................................................................21
DIMENSIONS...................................................................................................22
TECHNICAL DATA...........................................................................................23
2. CONNECTION TO TRACTOR......................................................................................24
THE HYDRAULIC SYSTEM.............................................................................24
Hydraulic connection............................................................................24
Connection of electric system ..............................................................25
ELECTRIC CONTROL .....................................................................................26
Functions .............................................................................................26
MOUNTING OF LIFT SUSPENSION ...............................................................29
CONNECTION AND DISCONNECTION OF PRECISION CHOPPER.............32
3. MOUNTING OF EQUIPMENT.......................................................................................34
HITCH FOR TRAILER......................................................................................34
PICK-UP...........................................................................................................36
CHUTE AND DEFLECTOR..............................................................................37

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4. ADJUSTMENTS............................................................................................................39
PICK-UP...........................................................................................................39
OPENING OF ROTOR HOUSING....................................................................41
ROTOR AND ROLLER SECTION....................................................................44
Cutting lengths.....................................................................................47
REPLACEMENT AND ADJUSTMENT OF BLADES........................................48
GRINDING........................................................................................................51
Rough grinding.....................................................................................54
REVERSE ........................................................................................................55
5. DRIVING IN THE FIELD................................................................................................56
GENERAL CONDITIONS.................................................................................56
Swathing before chopping....................................................................56
TRANSPORT POSITION .................................................................................57
STARTING IN THE FIELD................................................................................58
Blockage in the machine......................................................................59
VARIOUS .........................................................................................................61
6. MAINTENANCE............................................................................................................62
IN GENERAL....................................................................................................62
GUARDS..........................................................................................................63
REPLACEMENT OF BLADES..........................................................................63
TYRE PRESSURE ...........................................................................................63
FRICTION CLUTCH.........................................................................................64
FUSE................................................................................................................66
VARIOUS .........................................................................................................67
Rollers..................................................................................................67
Chain tightener for pick-up auger.........................................................67
7. GREASING ...................................................................................................................69
8. STORAGE (WINTER STORAGE).................................................................................70
10. SPARE PARTS ORDERING.......................................................................................71
11. DISPOSAL ..................................................................................................................72
12. FAULT FINDING.........................................................................................................73
DIAGRAMS: .....................................................................................................73
CONTROL SYSTEM ........................................................................................74
WIRING SYSTEM.............................................................................................75
13. WARRANTY................................................................................................................76

1. INTRODUCTION
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1. INTRODUCTION
INTENDED USE
The precision chop forage harvester FC 860 is solely constructed and
manufactured for the usual work in agriculture, i.e.: Usual work in fields where
you want to gather and chop green crops such as maize, grass or whole crop which
are to be used for silage production intended for coarse fodder for cattle.
The machine should only be connected to a tractor which corresponds with the
specifications of the product and is legal to use.
Any use beyond this is outside the intended use. Kongskilde Industries A/S is
not responsible for any damage or injury resulting from such use; the user
bears that risk.
It is assumed that the work is performed under reasonable conditions, i.e. that the
fields are cultivated normally and to a reasonable extent kept clear of foreign matter
and debris.
Intended use also means that the instructions given by Kongskilde Industries A/S in
the instruction manual and the spare parts book are observed and that thorough
agricultural knowledge and technically correct use is a matter of course.
The precision chop forage harvester FC 860 should only be used, maintained
and repaired by persons who, through relevant instructions and after reading
the instruction manual, are familiar with the machine and, in particular, are
informed of possible dangers.
In the following there are a number of general and special safety instructions which
must be observed altogether.
If any changes are made on the machine and its construction without permission
from Kongskilde Industries A/S, Kongskilde Industries A/S cannot be held
responsible for any damage or personal injury resulting from this.

1. INTRODUCTION
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PERFORMANCE
The FC 860 is capable of working alone or parallel with other machines.
FC 860 has a high capacity compared with other corresponding products as it uses
the “UPPER CUT” system. “UPPER CUT” gives a minimum loss of power when
cutting the material and thus ensures maximum utilisation of the accessible tractor
power.
Capacity, however, is difficult to define and compare as, for a forage harvester, it will
depend not just on which crop is being cut but also how the crop has been treated
before it is picked up or cut by the machine and finally which cutting length
adjustment the machine is working with.
If we take a forage harvester which, in fresh, not pre-dried grass, can work 100 tons
per hour, it is possible to calculate the capacity at different per cents of dry matter
depending on the pre-treatment before cutting, as shown in the following table.
Dry matter
Capacity
Dry matter
100%
18 ton/h
Wet new grass
15%
120 ton/h
Not pre-dried grass
18%
100 ton/h
Pre-dried grass –no outflow of sap from clamp silo
25%
72 ton/h
Pre-dried grass –no outflow of sap from high tower silo
33%
55 ton/h
Very pre-dried grass
50%
36 ton/h
Straw, very dry
90%
20 ton/h
It will probably surprise most people that the capacity can vary between 20 and 120
ton/h, as a result of varying water content.
In practice you want to drive the forage harvester in the highest possible tractor gear
without causing frequent blockage. However, the amount of grass in the field will
always vary, for instance where the mower conditioner has had to turn, change
forward speed or change direction of travel. Therefore it is often appropriate either to
drive with a power reserve so that the machine will not block, or to continuously
adapt the driving of the forage harvester to the conditions.
The pick-up unit and the feed rollers are both secured against overloading resulting
from a blockage by means of a friction clutch. The forage harvester also has a
reverse function which makes it possible to remove a blockage without having to
leave the tractor seat.
The intention is that the inexperienced user increases the forward speed gradually in
the beginning until the pick-up is blocked; releases the blockage again by reversing
and chooses a tractor gear at a suitable lower level to reduce the risk of blockage.

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However, it is not the intention that the clutch function of the feed rollers releases. If
this happens, the clutch adjustment of the pick-up must be reduced. The same will
apply if the main friction clutch between the tractor and the machine releases during
normal working. If it is not the pick-up unit which is blocked, the adjustment of the
machine is incorrect.
Unfortunately it has been seen that the torque adjustment of the friction clutch of the
pick-up unit has been increased to the point where it is the friction clutch between the
machine and the tractor which releases frequently. The main friction clutch is not
intended to release frequently but only for starting shock or when foreign matter gets
into the machine. The same applies to the friction clutch for the feed intake rollers.
The main clutch simply cannot absorb the heat which is generated during these long
releases. The power transmitted at the main clutch will be at least 10 times higher
than the power needed to drive the pick-up unit.
Only the pick-up unit can be seen from the tractor and therefore it should be released
first when there is a blockage. The experienced user will be able to adapt the driving
of the tractor to the amount of grass and thus work with less capacity reserve and,
generally, have a greater output.
The cutting length of the forage harvester can be adjusted and adapted to the crop in
question. The cutting length is usually reduced when cutting whole crops to ensure
greater damage of the grains. The shorter cutting length will of course require more
power for which reason there will be a lower output when cutting whole crop than
when cutting grass, though it is difficult to compare.
The power requirements are also increased when the blades are worn and the shear-
bar clearance is increased. It is necessary to sharpen the blades and adjust the
shearbar during the season.

1. INTRODUCTION
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SAFETY
The safety of persons and machines is an integral part of Kongskilde’s development
work. However, damage can occur as a consequence of misuse and insufficient
instruction. We wish to ensure the safety of you and your workforce in the best
possible way, but this also requires an effort on your part.
A forage harvester cannot be constructed in such a way that it guarantees the full
safety of persons and at the same time performs efficiently. This means that it is very
important that you as user of the machine pay attention and use the machine
correctly and thereby avoid exposing yourself and others to unnecessary danger.
As described above the machine is only intended for one purpose, namely:
Chopping grass and similar green crops, for feeding purposes.
It is assumed that the work is performed under reasonable conditions, i.e. that the
fields are cultivated normally and to a reasonable extent kept clear of foreign matter
and debris.
The machine demands skilled operation, which means that you should read the
instruction manual before you connect the machine to the tractor. Even though
you have been driving a similar machine before, you should read the manuals - this
is a matter of your own safety!
You should never leave the machine to others before you have made sure that they
have the necessary knowledge.

1. INTRODUCTION
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DEFINITIONS
The safety decals and the instruction manual of the machine contain a line of safety
notes. The safety notes mention certain measures, which we recommend you and
your colleagues to follow as to increase the personal safety as much as possible.
We recommend that you take the necessary time to read the safety instructions and
inform your staff to do the same.
In this instruction manual this symbol is used with reference to
personal safety directly or indirectly through maintenance of the
machine.
CAUTION: The word CAUTION is used to ensure that the operator follows the
general safety instructions or the measures mentioned in the
instruction manual to protect the operator and others against injuries.
WARNING: The word WARNING is used to warn against visible or hidden risks,
which might lead to serious personal injuries.
DANGER: The word DANGER is used to indicate measures which, according to
legislation, must be followed to protect the driver and others against
serious injuries.

1. INTRODUCTION
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GENERAL SAFETY INSTRUCTIONS
The following is a brief description of the measures, which should be a matter of
common knowledge to the operator.
1. Always disengage the PTO drive shaft, activate the parking brake and stop the
tractor engine before you
-lubricate the machine,
-clean the machine,
-disassemble any part of the machine,
-adjust the machine.
2. Always block the wheels before working under the machine.
3. Never start the tractor until all persons are at a safe distance away from the
machine.
4. Make sure that all tools have been removed from the machine before starting
the tractor.
5. Make sure that all guards have been mounted correctly and locked where
appropriate.
6. During work never wear loose clothes or have your hair hang down as it may be
pulled in by the moving parts of the machine.
7. Always wear suitable shoes to avoid falling.
8. Do not change the guards or work with the machine when a guard is missing or
defective.
9. Always drive with the statutory lights and safety marking during transport on
public roads and at night.
10. Limit the transport speed to maximum 30 km/h if the machine has not been
marked with another maximum speed limit.
11. Do not stand near the machine while it is working.
12. When mounting the PTO drive shaft, check that the number of rpm and the
direction of rotation of the tractor match those of the machine.
13. Always use hearing protectors if the noise from the machine is annoying or if
you are working with the machine for a considerable period in a tractor cabin,
which has not been silenced sufficiently.

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14. Never allow anybody to be on the machine during work or transport.
15. Never use the machine for other purposes than what it has been constructed
for.
16. Do not allow any children to be near when you are working with the machine.
17. Never stand between the tractor and the machine during connection and
disconnection.
18. Do not feed material into the cutting unit, using hands or feet, while it is working.
19. Do not try to remove material from the cutting unit while it is working.
20. If material must be removed from the forage harvester, the PTO shaft must be
disconnected completely. Stop the tractor engine before removing any material
from the forage harvester.

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LOCKING OF GUARDS
All hinged guards on the machine are equipped with a lock. The lock ensures that the
guard cannot be opened without tools. There are two different types of lock. Fig. 1.1
and 1.2 show the two locking principles and the corresponding transfers which
indicate and illustrate the locks on the machine.
CHOICE OF TRACTOR
Always follow the recommendations specified in the instruction manual of the tractor.
If this is not possible, technical assistance must be sought.
Choose a tractor which has minimum 55 KW/75 HP at the power take-off but cannot
deliver more than 92 KW/125 HP.
The machine is as standard constructed for 540 RPM or 1000 RPM, and is delivered
from the factory with 1 3/8" PTO drive shaft with 21 splines yoke. As an alternative 1
3/8’’ yoke with 6 splines can be supplied for the PTO drive shaft of the machine
A suitable tractor will have a good range of gears for driving speeds between 5 and 8
km/h.
The tractor hydraulic system should deliver at least 170 bar and the adjustable relief
valve should not allow more than 210 bar.
The following hydraulic outlets are necessary depending on the equipment used:
1
Single-acting
Pick-up lifting
1
Double-acting
Adjustable hitch
It is important that there is direct access to the 12-volt battery of the tractor and that it
is in a good condition.
Always choose a tractor with a closed cabin when working with a precision chopper.
Fig. 1-1
PR11-0243
PR80-0819 Guard
Fig. 1-2
PR11-0244
PR80-0820
Guard

1. INTRODUCTION
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CONNECTION AND DISCONNECTION
Always make sure that nobody is standing between
the tractor and the machine during connection and
disconnection. An unintentional manoeuvre with the
tractor may cause serious injury (see fig. 1-3). When
disconnecting it is important that the ground is even
and stable so that the machine does not move and
injure persons or cause damage to other equipment.
The same precautions must be taken when connecting/disconnecting trailers by
means of the hitch hook at the rear of the forage harvester.
Check that the machine is intended for the number of rpm of the tractor PTO. A
wrong number of rotations over a long period may damage the machine and at worst
result in ejection of parts through the delivery chute.
Make sure that the PTO drive shaft has been mounted correctly, i.e. that the lock pin
is in mesh and that the support chain has been fastened at both ends.
The PTO drive shaft must be correctly protected. If the guard is damaged it must be
replaced immediately.
IMPORTANT: Before connecting the trailer to the hydraulic hitch, always:
- Disengage the PTO.
- Wait until all moving parts have stopped.
Check that all hydraulic couplings are tight and that all hoses and fittings are
undamaged before activating the hydraulic system.
Make sure that there is no pressure in the hydraulic hoses when these are
disconnected from the tractor.
Hydraulic oil under pressure can penetrate the skin
and cause serious infections. You should always
protect the skin and the eyes against oil splashes
(see fig. 1-4). If, by accident, hydraulic oil under
pressure hits you, consult a doctor immediately.
Fig. 1-3
Fig. 1-4

1. INTRODUCTION
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ADJUSTMENT
IMPORTANT: Before adjusting the machine, always:
- Disengage the PTO from the tractor.
- Stop the tractor engine
- Wait until all moving parts have stopped.
It is important not to remove the guards until all revolving parts have stopped. This
especially applies to the delivery chute above the chopping cylinder.
If the cutting parts in the blade cylinder must be adjusted or replaced, it is important
to block the blade cylinder as the sharp blades can easily cause injury.
Before working, check that the feed rollers and the blade cylinder can move freely.
Also check that the blades are intact and without cracks. Damaged blades must be
replaced to prevent them from blocking or damaging the machine and to avoid metal
parts being thrown out from the delivery chute.
Check periodically if blades and blade bolts are worn according to the rules in the
instruction manual.
IMPORTANT: The first time you use the machine the blades and blade bolts may
"bed in". For this reason you must check and tighten the blade bolts
after the first working hour.
When lifting the delivery chute above the blade cylinder make sure that nobody is in
danger of being hit by the guard. When lifting the guard, hold on to the hoop which is
fastened to the intermediate guard with both hands.

1. INTRODUCTION
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TRANSPORT
Limit the transport speed to maximum 30 km/h if the machine has not been marked
with another maximum speed limit.
Always check that mechanical transport safety devices are activated before transport
with trailed implements.
DANGER: Never let anyone stand or sit on the machine, especially not when
you are driving.
Fig. 1-5 The pick-up of the forage harvester must be secured mechanically before transport.
The statutory lighting and traffic markings must be placed correctly, on the forage
harvester as well as the trailer.
Reflectors and lighting must be cleaned regularly.
Fig. 1-5

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WORKING
Before you start working make sure that no persons are behind the forage harvester
due to the danger of being hit by metal parts from damaged blades.
Also make sure that there are no persons in the trailer used for picking up. There is
danger of suffocating in the flow of material or getting hit by metal parts.
If the feed rollers or the blade cylinder are blocked, disengage the clutches and stop
the tractor engine immediately. Activate the parking brake and wait until the revolving
parts have stopped before removing the material or the foreign matter.
This cannot be said often enough: Never remove material blocked in the machine
while the machine is running and never feed material into the pick-up with your hands
or feet as there is a serious danger of getting caught and pulled into the harvester
which would cause dismemberment or death.
Therefore, never allow anyone to stand near the forage harvester while it is working,
especially not children who do not know the danger and do unforeseen things.
PARKING
Remember to block the wheels if there is a risk that the machine will move after
parking.
Remember to remove hydraulic hoses and electric cables before driving away with
the tractor.
GREASING
When greasing or maintaining the machine never let more than one person work at
the machine at a time. This reduces the risk of getting fingers caught because
another person by accident turns the revolving parts while you are still working with
them.
Never try to clean, grease or adjust the machine before the PTO has been
disengaged, the tractor engine has stopped and the parking brake been activated.
Remove the ignition key!

1. INTRODUCTION
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GRINDING
When grinding always follow this procedure:
- Stop the tractor engine
- Activate the parking brake.
- Wait until all moving parts have stopped.
It is necessary to remove some of the guards to change the direction of rotation of
the rotor when grinding the blades. As there are chain and belt transmissions your
hands may be injured if the revolving parts have not stopped before the guards are
removed.
Grinding is performed according to the following procedure:
1. Check if the grindstone is undamaged and if the device is able to move back
and forth easily.
2. Lower the guard behind the grinding device to give access to the blade cylinder.
3. Adjust the stone and place the guard of the grinding device again.
4. Remove the guard above the blade cylinder transmission and change the
direction of rotation of the rotor.
5. Fasten the guard again and check that there are no persons near the machine.
6. Start the tractor again and keep the rpm close to idling.
7. Perform the grinding carefully.
Always use safety glasses when grinding as small particles from the grindstone might
hit you.
When grinding has finished, stop the tractor engine, change the direction of rotation
and fasten all guards.
REMEMBER: Only grind with all guards closed!

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Fig. 1-6
PR11-0232
Min. 12 mm
MAINTENANCE
After approx. 2 days of operation, all bolts should be re-tightened.
Always make sure that the replacement spare parts are tightened to the correct
torque.
Hydraulic hoses must be checked by an expert before use, and after that, a minimum
of once a year. If necessary, they must be replaced. The working life of hydraulic
hoses should not exceed 6 years, including maximum 2 years of storage.
When replacing, always use hoses which comply with the requirements stated by the
manufacturer. All hoses are marked with date of production.
REPLACEMENT OF WEARING PARTS
Blades, blade bolts and shear-bar are made of high-alloyed, heat-treated materials.
This heat treatment provides especially hard and ductile material which is able to
withstand extreme stress. Damaged blades, blade bolts or shear-bars must be
replaced by original KONGSKILDE spare parts only to ensure safe operation.
Blades and blade bolts must be checked every
day during the season.
The special blade bolts must be tightened with a
torque wrench to 40 kgm.
When the blades have been worn max. 8 mm or
approx. 12 mm above the straight piece, they
must be replaced (see fig. 1-6).
After replacement of blades, blade bolts and the like, check that no tools have been
left in the machine.

1. INTRODUCTION
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