KUHN FC 202 R User manual

ASSEMBLY / OPERATOR'S
MANUAL
FC 202 - FC 202 R
N° 95101 A.GB - 06.1999

DEAR OWNER,
In buying a KUHN machine you have chosen wisely. Into it have gone yea s of thought,
esea ch and imp ovements. You will find, as have thousands of owne s all ove the wo ld, that
you have the best that enginee ing skill and actual field testing can p oduce. You have
pu chased a dependable machine, but only by p ope ca e and ope ation can you expect to
eceive the pe fo mance and long se vice built into it.
This manual contains all the necessa y info mation fo you to eceive full efficiency f om you
machine. The pe fo mance you get f om this machine is la gely dependant upon how well you
ead and unde stand this manual and apply this knowledge. Please DO NOT ASSUME THAT
YOU KNOW HOW TO OPERATE AND MAINTAIN YOUR MACHINE befo e eading this
manual ca efully. KEEP THIS MANUAL AVAILABLE FOR REFERENCE.
You KUHN deale will inst uct you on the gene al ope ation of you machine. He is inte ested
that you get the best pe fo mance possible and will be glad to answe any special questions
that may a ise ega ding the ope ation of the KUHN machine.
You KUHN deale can offe a complete line of genuine KUHN se vice pa ts.
These pa ts a e manufactu ed and ca efully inspected in the same facto y that builds the
machine to assu e high quality and accu ate fitting of any necessa y eplacements.
When o de ing se vice pa ts it is impo tant that you indicate the type of machine conce ned
and its se ial numbe .
Fo this eason please complete the model identification plate diag am below with the equi ed
info mation. This will p ovide you with an easy efe ence fo futu e se vice pa ts o de s.
ABOUT IMPROVEMENTS
KUHN is continually st iving to imp ove its p oducts and, the efo e, ese ves the ight to make
imp ovements o changes when it becomes p actical to do so, without incu ing any
obligations to make changes o additions to the equipment sold p eviously.

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CONTENTS
SAFETY 2
SAFETY DECALS 8
INTRODUCTION 10
TECHNICAL SPECIFICATIONS 11
ASSEMBLY INSTRUCTIONS 12
ATTACHMENT TO THE TRACTOR 15
PTO SHAFT 16
WORKING POSITION AND ADJUSTMENTS 17
TRANSPORT AND PARKING POSITION 21
OPERATION 22
MAINTENANCE 23
CONDITIONING : - FC 202 24
- FC 202 R 26
SECURING DISCS AND KNIVES 27
INSPECTION OF KNIVES AND SECURING ELEMENTS 28
LUBRICATION 30
OPTIONAL EQUIPMENT 32
STORAGE 34
TROUBLE SHOOTING 35
LIMITED WARRANTY 37
Copyright 1999 KUHN S.A.

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SAFETY
The symbol above is used throughout this ma ual every time recomme datio s are made co cer i g your safety,
the safety of others, or the good operatio of the machi e.
These recomme datio s must be made k ow to all machi e operators.
DESIGNATED USE OF THE MACHINE
FC 202 - FC 202 R M o we r C o ditio ers must o ly be used for the work which they have bee desig ed
: mowi g o the grou d of hay fields, grass silage fields a d improved pastures for the purpose of harvesti g fodder
for feedi g livestock.
The ma ufacturer is ot held liable for a y damage resulti g from machi e applicatio s other tha those specified
by the ma ufacturer.
A y use other tha the desig ated operatio is at the risk a d respo sibility of the operator.
Desig ated use of the machi e also mea s :
- followi g operatio , mai te a ce a d repair recomme datio s give by the ma ufacturer ;
- usi g o ly ge ui e spare parts, equipme t a d accessories as desig ated by the ma ufacturer.
FC 202 - FC 202 R Mower Co ditio ers must o ly be operated, mai tai ed a d repaired by compete t perso s
who are familiar with machi e specificatio s a d operatio a d are aware of a y da ger i volved.
The operator must imperatively respect curre t legislatio co cer i g :
- accide t preve tio ,
- work safety,
- public traffic circulatio .
All safety advice i dicated o the machi e must be strictly observed.
The ma ufacturer is ot held liable for a y damage resulti g from machi e modificatio s carried out by the operator
himself or by a third party without previous writte agreeme t from the ma ufacturer.
GENERAL SAFETY RECOMMENDATIONS
Before operati g the machi e, always e sure that tractor a d machi e are i accorda ce with work safety a d road
traffic regulatio s.

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BASIC PRINCIPLES
1. I additio to the recomme datio s give i this ma ual, legislatio o work safety a d accide t preve tio must
also be respected.
2. Advice is i dicated o the machi e, specifyi g safety recomme datio s i order to preve t accide ts.
3. Before travelli g o public roads, the operator must e sure that the machi e co forms to road traffic regulatio s.
4. Before starti g work, the operator must be familiar with all machi e co trols, ha dli g devices a d their
fu ctio s. O ce at work, it is too late to do so !
5. Do ot wear loose clothi g which could become caught up i movi g eleme ts.
6. Use a tractor equipped with a safety cab. Keep wi dows a d roof hatch closed for reduced sou d level while
operati g the PTO drive impleme t.
7. Before starti g up the machi e a d begi i g work, check the surrou di g area (beware of childre !). Make
sure there is sufficie t visibility. Keep all people a d a imals away from the da ger zo e of the machi e (risk
of projectio !)
8. Carryi g people or a imals o the machi e whe worki g or i tra sport is strictly forbidde .
9. Machi e must o ly be attached to tractor usi g mea s provided a d i accorda ce with curre t safety
sta dards.
10. Whe attachi g or removi g the machi e, place the parki g sta d i to the correspo di g positio .
11. Special care should be take whe attachi g or removi g the machi e from the tractor.
12. Before attachi g the machi e, make sure that the maximum permitted fro t axle weight a d gross weight of
the combi atio are ot exceeded.
13. Do ot surpass the maximum permitted le gth a d width authorized by road traffic regulatio s.
14. Before tra sporti g the machi e o public roads, e sure that all legally required guards a d i dicators (lights,
reflectors ...) are i place a d i good operatio .
15. All operati g co trols (cords, cables, rods ...) must be positio ed so that they ca ot be set off accide tly,
riski g accide t or damage.
16. Before tra sport o public roads, locate the machi e i to its tra sport positio as i structed i this operators
ma ual.
17. Never leave the tractor seat while the machi e is operati g.
18. Drive speed must be adapted to grou d co ditio s as well as roads a d paths.
Always avoid abrupt cha ges of directio .
19. Precisio steeri g, tractor adhere ce, road holdi g a d efficie t braki g are i flue ced by the type of impleme t,
weight, ballast of fro t axle, grou d or road co ditio s. It is therefore of utmost importa ce to be cautious i
every give situatio .

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20. Be particularly cautious whe tur i g cor ers, payi g atte tio to machi e overha g, le gth, height a d weight.
21. Before operati g the machi e, e sure that all safety guards are firmly i place a d i good co ditio . If wor
or damaged, replace immediately.
22. Before operati g the machi e, check tight ess of uts a d bolts, particularly o tool fixi g eleme ts (blades,
ti es, k ives, spades ...). Retighte if ecessary.
23. Keep clear of the machi e operati g area.
24. WARNING ! Da ger of crushi g a d sheari g ca exist whe compo e ts are operated by hydraulic or
p eumatic co trols.
25. Before leavi g the tractor or before adjusti g, mai tai i g or repairi g the machi e, tur off the e gi e, remove
ig itio key a d wait u til all movi g parts have come to a complete stop.
26. Do ot sta d betwee the tractor a d the machi e u less the ha d brake is tight a d/or stops have bee placed
u der the wheels.
27. Before a y adjustme ts, mai te a ce or repairs are carried out, e sure that the machi e ca ot be started
up accide tally.
ATTACHMENT
1. Whe attachi g or removi g the machi e from the tractor, positio hydraulic lift co trol lever i such a way that
it ca ot be set off accide tally.
2. WARNING ! Da ger of crushi g a d sheari g ca exist i the lifti g zo e of the 3-poi t li kage !
3. Do ot sta d betwee the tractor a d the machi e whe operati g the outer co trol lever of the lift mecha ism.
4. I tra sport, the machi e lift mecha ism should be stabilized by tractor tie rods to avoid floatatio a d side
shifti g.
5. Whe tra sporti g the machi e i the raised positio , lock the lift co trol lever i place.
POWER TAKE-OFF

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1. O ly use PTO shaft supplied with the machi e or recomme ded by the ma ufacturer.
2. PTO guards must always be i place a d i good co ditio .
3. Check for correct PTO overlap whe at work a d i tra sport.
4. Before attachi g or removi g the PTO shaft, dise gage PTO shaft, tur off e gi e a d remove ig itio key.
5. If a primary PTO shaft is equipped with a slip clutch or a free wheel, these must be fitted o the machi e PTO.
6. E sure that PTO shaft is always correctly fitted a d locked i to place.
7. Make sure guards are correctly i place a d secured with the safety chai s provided.
8. Before e gagi g PTO, e sure that PTO speed (rotational frequency) a d directio of rotatio are i accorda ce
with ma ufacturer's recomme datio s.
9. Before e gagi g PTO, keep all people a d a imals clear from the machi e.
10. Never e gage PTO shaft whe tractor motor is tur ed off.
11. Never surpass PTO a gle recomme ded by the ma ufacturer.
12. WARNING ! Rotati g eleme ts ca co ti ue tur i g mome tarily after PTO is dise gaged. Keep clear u til all
rotati g eleme ts are at a sta dstill.
13. Whe removi g the machi e, locate PTO shaft o the supports provided.
14. Fit safety cap o tractor PTO.
15. Replace a y wor or damaged PTO guards immediately.
Rotatio speed ... rpm (America Measure) is also expressed i metric measure : Rotatio al freque cy ... mi - 1 . Both
u its are equivale t, for example : Rotatio speed 540 rpm equals Rotatio al freque cy 540 mi -1.

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MAINTENANCE
1. Before checki g a y machi e malfu ctio a d before adjusti g, mai tai i g or repairi g the machi e, dise gage
PTO, tur off e gi e a d remove ig itio key.
2. Check tight ess of uts a d bolts regularly. Retighte if ecessary.
3. If the machi e is raised, prop it up i a stable positio before carryi g out a y mai te a ce work.
4. Whe replaci g a worki g part, wear protectio gloves a d o ly use sta dardized tools.
5. It is forbidde to discard a y oil, grease or filters. These must be give to waste disposal orga isatio s to protect
the e viro me t.
6. Disco ect power source before a y work is do e o the electric system.
7. Check safety guards regularly, particularly those that are subject to wear. Replace immediately if damaged.
8. Spare parts used must be i accorda ce with specificatio s a d sta dards as defi ed by the ma ufacturer. Use
o ly ge ui e KUHN parts !
9. Before a y electric weldi g is carried out o tractor or attached machi e, disco ect ge erator a d battery
termi als.
10.Repairs o eleme ts u der pressure or te sio (spri gs, accumulators etc.) must o ly be carried out by
compete t perso s with sta dardized equipme t.

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SPECIAL SAFETY RECOMMENDATIONS
1. Use a tractor equipped with a e closed cab with wi dows made of safety glass a d kept closed. It is
recomme ded to fit polycarbo ate scree s i side the tractor safety cab's side a d rear wi dows or to i stall
mesh guards o the exterior of them.
2. Stay a safe dista ce away from the mower co ditio er whe discs are rotati g.
3. For safe machi e operatio , it is imperative that cutti g tools be fitted i accorda ce with the ma ufacturers
recomme datio s. Use o ly the tool outfit supplied with the machi e.
4. Each time before usi g the mower co ditio er, i spect co ditio of cutti g eleme ts (k ives, discs). Replace
a y missi g, wor or damaged cutti g eleme ts immediately. Use o ly ge ui e KUHN spare parts.
5. To avoid creati g da gerous out of bala ce forces, always replace missi g, damaged or wor k ives i pairs.
6. Whe replaci g k ives or discs, systematically i spect their securi g eleme ts as per the ma ufacturers
recomme datio s.
7. Regularly i spect the disc mowers protectio cover. Wor or damaged protectio covers must be replaced
immediately.
8. Protectio devices (such as guards, shields etc.) are i te ded to preve t sto es, rocks or other foreig objects
from bei g projected. They also preve t access to the machi es da ger zo es. Therefore, it is imperative that
protectio devices are put i place a d properly secured each time before usi g the machi e.
9. Crushi g a d sheari g zo es which could cause serious bodily i jury whe cha gi g the machi e from
tra sport to work positio a d vice versa may exist. To preve t possible i jury, be extra careful whe
ma euveri g a d e sure that everyo e is at a safe dista ce away from the machi e.
10. PTO drive to the mower co ditio er must ever be e gaged u less the cutterbar skid shoes are i co tact with
the grou d a d the protective cover is folded dow .
11. Grou d of the pastures to be mow must be free of foreig objects.
12. Eve whe the machi e is used i accorda ce with it purpose, objects may be projected. It is therefore
imperative that everyo e be kept away from the da ger zo e, that extra care be take a d that extra precautio
(such as safety i dicators) be take whe mowi g pastures alo gside roads or ear public areas (parks,
schools etc.).
13. Never mow i reverse.
14. Whe dise gagi g the PTO drive, movi g parts co ti ue to rotate for some time. Wait for all movi g parts to
come to a complete stop before approachi g the machi e.
15. If a obstructio is hit, stop the tractor immediately, dise gage PTO drive, tur off e gi e, remove ig itio key
a d wait for all movi g parts to come to a complete stop.
Check the e tire machi e for a y damage before resumi g work.
16. It is stro gly recomme ded to have your machi e checked by your dealer after each seaso , especially blades
a d discs a d their fixi g devices ( uts, bolts etc.).

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SAFETY DECALS
THE FOLLOWING SAFETY PICTORIALS HAVE BEEN PLACED ON YOUR MACHINE IN THE AREAS
INDICATED. THEY ARE INTENDED FOR YOUR PERSONAL SAFETY AND FOR THE SAFETY OF THE
PEOPLE WORKING WITH YOU. THE TEXT SHOWN ON THEM GIVES THEIR PRECISE MEANING.
KEEP THE PICTORIALS LEGIBLE. IF THEY ARE NOT, REPLACE THEM.

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The KUHN Mower Conditioner fitted with conditioning rotor complete with free swinging
fingers and adjustable comb has been specially designed for natural grasses but also
gives excellent results when mowing and conditioning grass and clover mixed crops.
KUHN Mower Conditioners fitted with roller conditioners are particularly suitable
for working in lucerne / alfalfa and clover crops.
The instability of the weather makes the preparation of good hay precarious.
Consequently we have designed the KUHN Mower Conditioner to speed the drying cycle
by some 50 % on natural grasses with the subsequent added advantage of reducing to
a minimum the risk period during which the hay is exposed to the vagaries of the
weather.
Making hay by conventional methods needs 3 to 5 days after mowing ; the Kuhn Mower
Conditioner in reasonable weather will reduce the moisture content to 20% in 1 1/
2 to 2 days or it will prepare wilted grass for silage reducing the moisture content
to 60% in 4 to 5 hours.
To obtain the very best hay quality from your crop, you should, after using the Mower
Conditioner, leave the grass for 1 to 2 hours and then use a tedder on it twice.
For example, if cutting took place at 6 or 7.30 am, then it should be tedded at 9.00
am and again at 11.00 am. If this practice is followed, with good weather, the crop
can very often be baled the same evening and the hay will retain the maximum food
value.
Never wait too long before tedding, otherwise the outer layer of hay becomes too dry
with increased losses and the total drying time will be delayed.
Acceleration of the drying process.
INTRODUCTION

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FC 202 FC 202 R
Attachment 3-point cat. 2
Power requirement (at PTO). As from 55 hp (40 kW)
Transport position Pivoted to the rear in line with the tractor
- overall width 4’11" (1500 mm)
- overall length 8' 3" (2500 mm)
Working position To the rear right-hand side of the tractor
- overall width 10' 6" (3200 mm)
Cutting system 4 discs
- cutting width 6' 7" (2000 mm)
- work rate 3.7 to 5 acres/hr (1.5 to 2 hectares/hr)
Rotation of discs 2600 rpm
(min-1 )
Conditioning system Rotor with free swinging 2 conditioning rollers
fingers,reversible and which exert contact
adjustable conditioning pressure on the crop
comb
Width of conditioning rotor 1250 mm (4’1") 1225 mm (4')
(finger type or roller type
conditioner)
Speed (rotational frequency) of 1000 rpm (min-1 ) 810 rpm (min-1 )
the conditioning rotor (FC
finger type or roller type
conditioner)
PTO speed (rotational frequency) 540 rpm (min-1 )
Swath adjustment 2 swath screens and 1 adjustable rear shield
Swath width 700 - 1300 mm (2’3" - 4’3")
Weight with PTO shaft 745 kg (1639 lbs) 804 kg (1769 lbs)
Primary PTO shaft with free wheel (overrun clutch)
Optional extra - Rigidified blades
- Signalling elements
- Additional suspension spring
(only for FC 202 R)
TECHNICAL SPECIFICATIONS

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To facilitate transportation, a certain number of parts are not fitted to the
machine.
To fit these, proceed as follows :
Assembly of guards (photos 1 and 2)
- Mount bar (A) to tube (B) and the
support arm (C) to drive tube (D).
- Secure the outer support (E) to bar (A)
and the inner support (F) to the support
arm (C) and guard (X).
- Mount the tie rod (G) to outer support
(E) and tube (B) as shown in photo 1.
V = screw M12x25 + washer + nut M12
W = screw M12x25 + washer
- Fit the front guard (H) and side guard
(I) using 5 special screws M10 x 25 +
washer 11 x 24 x 2, + self-locking nut
M10 as shown in photos 1 and 2.
Assembly of safety covers (photos 3 and
3A)
Unroll cover (K) and secure to the guard
tubes using straps (L) (photo 3).
Fit cord (Y). To do this, attach one end
of cord to the end of sliding lock (B)
(photo 4), thread through the eyelets
and attach handle (A) to the other end
(thread the cord through the handle and
tie a knot (photo 3).
Next attach safety covers together using
strap (E) (see photo 27 and fig. 28 on
page 18) and hook tensioner (D) on both
side shields as shown in photo 3A.
ASSEMBLY INSTRUCTIONS

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Fitting the safety guards
The safety guards increase safety distance.
These guards (1, 2 and 7) should be fitted as shown in the figure below :
3 = cup square bolt M 10 x 30
4 = plain washer dia. 11 x 24 x 2
5 = self-locking nut M 10
6 = plain washer dia. 10,5 x 32 x 2,5
Fitting the rear safety guard
(only for FC 202)
Fit the rear safety guard (P) to the rear
cover (C) with 3 bolts (D) (M 10 x 25)
(see photo opposite).

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Fitting the shock absorber and the PTO shafts (photos 4 and 5)
Fit shock absorber (T) with washer (M 8) and self-locking nut (M 8) (photo 4).
Fit the intermediate PTO shaft (M) to the primary gearbox (N) and secure the opposite
end with strap (O) (photo 4). Attach the safety chain (P) to protection cone (Q) in
order to stop the guards of the PTO shaft from rotating (photo 4). Fit the primary
PTO shaft (R) making sure that the free wheel (overrun clutch) is fitted to the machine
side (photo 5). Attach the safety chain (S) to the 3-point frame (U). Support the
PTO shaft (R) using hook (Z) (photo 5).

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ATTACHMENT

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To avoid accidents which could be serious, always check that the safety
guards are firmly in place and to prevent their rotation, attach the free
end of the safety chain to a fixed point (photos 4, 5 & 6). Replace
immediately worn or damaged guards, using genuine KUHN parts.
I. WORKING POSITION
Once at the place of work, the machine
should be lowered to a height of 25 cm
(10") from the ground and changed from
transport to its working position as
follows :
- Release the pivot restraint (M) by
removing locking pin (S) (photo 15).
- Locking pin (S) should then be fitted
in the second hole of the stop (L)
(photo 15).
- Pull cord (E) in order to free position
lock (F) and swing the machine forward
until it locks automatically into the
working position (photo 15).
Never stand between machine
and tractor when swinging ma-
chine from transport to work
position. Make sure there is
nobody between tractor and
machine during this operation.
Lower the machine to the ground and raise
lock (G) to release the spring
compensating system (H) (photo 16).
Adjust the tractor lower link arms (W &
W’) (photo 6, page 15) if necessary so
that the chassis of the 3-point frame is
parallel to the ground.
Raise the hydraulic lift linkage so that
the lower right-hand link pin is
approximately 50 cm (20") above the
ground. Connect the support chain (B) in
the highest possible hole position of
the attachment bracket (T) of the
tractor (photo 16).
Completely lower the tractor linkage.
Lenght adjustment is correct when :
- The cutterbar is resting on the ground.
- The chain (B) is tight.
- The right-hand lower link is
approximately 45 cm (18") from the
ground.
- The 3-point frame is horizontal and
vertical (square tube ‘K’).
- The left-hand lower link (I) is
approximately 55 cm (22") from the
ground.
Attention : Close the eye of support
chain (B) using roll pin
(photo 16).
WORKING POSITION AND ADJUSTMENTS

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Optimal working position is obtained when the support (K) (photo 16) is in the vertical
position and when the stop (L) is positioned in the middle of its stroke (photo 15).
If necessary, adjust tractor top link.
To finish, connect the intermediate
PTO shaft (N) to the secondary gear-
box (D) (photo 17).
II. ADJUSTMENT OF DOWNWARD PRESSURE OF CUTTERBAR AND CONDITIONING UNIT ON THE GROUND.
The downward pressure of the cutterbar and conditioning unit on the ground is
determined by the two suspension springs (O & O’) (photo 18) and correspond to a length
P = 60 mm (2 3/8") (photo 18).
The operator can, however, modify this setting slightly when working in extreme
conditions :
- soft and very wet ground :
reduce the downward pressure
of the cutterbar, reduce length
P.
- Very uneven land or working
at high speed : increase the
downward pressure of the
cutterbar, increase length P.
Adjustments should be carried
out with the cutterbar resting
on the ground and by adjusting
screws (O & O’) (photo 18). Do
not forget to retighten the
lock nuts (R & R’) (photo 18).
IMPORTANT : When operating the machine without the conditioning unit,the
compensating spring (O’) must be removed and length P adjusted to 100 mm
(4") for working in normal conditions.
The correct downward pressure of the cutterbar and conditioning unit will
prolong the life of the machine.