KUHN FC 4000 R Owner's manual

OWNER’S / OPERATOR’S MANUAL
FC 4000 R - FC 4000 RG
FC 4000 G
N° 95109 C.GB – 10.2004

Thank you for purchasing a new KUHN FC 4000 Disc Mower Conditioner. In purchasing a
newKUHN machine,youhavechosenwisely. Intoithavegoneyearsofresearchanddevelop-
ment, and we hope that you will enjoy years of productive use from it. You will find, as have
thousandsof ownersall overtheworldthatyouhavethebestthat modernengineering, produc-
tion,andfield-testing canproduce.
You have purchased a dependable machine, but only proper care, maintenance, operation,
safety can enable you to receive the top performance, and long service life built into it. The
performanceyougetfromthismachineislargelydependent uponhow wellyoureadandunder-
standthis manualandapply thisknowledge.
DONOTASSUMETHATYOUKNOW HOWTOOPERATEANDMAINTAINYOUR MACHINE
withoutreading thismanual carefullyand infull.
KEEP THIS MANUALAVAILABLE FOR REFERENCEATALLTIMES.
THISMANUAL SHOULDREMAINWITHTHEMACHINE WHENSOLD.
YourKUHN dealerwillinstructyou onthe generaloperationandmaintenanceofyourmachine.
YourKUHN dealer isinterestedthat you getthebest performanceandlongest life possibleout
ofyournewKUHN machine. Pleasecontact your KUHN dealershouldyou haveanyquestion
regardingyournewKUHN machineafterreadingthis manual, oratanytime thereafter.
Your KUHN dealer offers a complete line of genuine KUHN service parts. These parts are
manufacturedand carefullyinspected inthesamefactorythatbuiltyournewmachine toassure
highquality andaccuratefitting ofanynecessary replacements.
ABOUT IMPROVEMENTS
In the interest of progress, KUHN is continually striving to improve its products, and therefore
reservesitsright tochangeany specifications, designormaterials listedinthis manual without
prior notice. KUHN also reserves its right to make improvements on its products at any time
withoutanyobligationstomakechangesoradditionstoproductssoldpreviouslyand/oralready
inservice.
INTRODUCTION

- 1 -
TABLE OF CONTENTS
SAFETYRECOMMENDATIONS ___________________________________________________________ 2
DESIGNATED USEOFTHEMACHINE ___________________________________________________ 3
GENERALSAFETYRECOMMENDATIONS________________________________________________5
SPECIALSAFETYRECOMMENDATIONS________________________________________________ 10
SAFETYDECALS _____________________________________________________________________ 12
TECHNICALSPECIFICATIONS __________________________________________________________ 14
ATTACHMENT ________________________________________________________________________ 16
ATTACHINGTOTHETRACTOR ________________________________________________________ 16
1. Straight hitch Model_____________________________________________________________ 16
2. Gyrodineswivel hitchModel _______________________________________________________ 19
CHECKLIST _______________________________________________________________________ 22
TRANSPORT_________________________________________________________________________ 23
ADJUSTMENTS ______________________________________________________________________ 24
CUTTINGHEIGHTADJUSTMENT(S) ____________________________________________________ 24
HEADERFLOATATIONADJUSTMENT ___________________________________________________ 25
PTOSPEED_______________________________________________________________________ 26
FORWARDSPEED _________________________________________________________________ 27
WINDROWADJUSTMENTS ___________________________________________________________ 27
ADJUSTINGTHECONDITIONINGINTENSITY _____________________________________________ 30
FIELDOPERATIONS __________________________________________________________________ 33
LUBRICATION________________________________________________________________________ 35
LUBRICATIONCHART _______________________________________________________________ 35
GREASEFITTINGS _________________________________________________________________ 36
GEARBOXES ______________________________________________________________________ 40
MAINTENANCE _______________________________________________________________________ 46
BLADEANDBOLTINSPECTION _______________________________________________________ 47
BLADEREPLACEMENT _____________________________________________________________ 49
DISCS ___________________________________________________________________________ 50
SKIDSHOES ______________________________________________________________________ 51
FRICTIONSLIPCLUTCH _____________________________________________________________ 52
DRIVECHAIN FORTHEUPPER ROLLS _________________________________________________ 53
HYDRAULICS ______________________________________________________________________ 54
ELECTRICCONNECTORS ____________________________________________________________ 56
FASTENERTORQUECHART _________________________________________________________ 57
OPTIONALEQUIPMENT _______________________________________________________________ 58
STORAGE ___________________________________________________________________________ 59
TROUBLESHOOTINGGUIDE ____________________________________________________________ 60
LIMITEDWARRANTY __________________________________________________________________ 64
NOTES _____________________________________________________________________________ 67
Copyright2002 KUHNS.A.

- 2 -
SAFETY RECOMMENDATIONS
TAKE NOTE! THIS SAFETYALERT SYMBOL FOUND THROUGHOUT THIS MANUAL IS
USED TO CALL YOUR ATTENTION TO INSTRUCTIONS INVOLVING YOUR PERSONAL
SAFETY AND THE SAFETY OF OTHERS. FAILURE TO FOLLOW THESE INSTRUC-
TIONS CAN RESULT IN INJURY OR DEATH.
THISSYMBOL MEANS
-ATTENTION!
- BEALERT!
- YOUR SAFETY IS INVOLVED!
SIGNAL WORDS :
Note the use of the signal words DANGER, WARNING, CAUTION with the safety messages.
Theappropriatesignal word for eachhasbeenselected using the followingguidelines :
DANGER : Indicatesan imminentlyhazardoussituation that,ifnotavoided,will resultindeath
or serious injury. This signal word is to be limited to the most extreme situations typically for
machinecomponents which,forfunctional purposes,cannotbe guarded.
WARNING : Indicatesapotentiallyhazardoussituationthat,ifnotavoided, couldresultindeath
orserious injury,andincludeshazards thatare exposedwhenguardsareremoved. Itmayalso
beusedtoalert against unsafe practices.
CAUTION : Indicatesa potentiallyhazardoussituationthat,if notavoided,mayresultin minor
ormoderateinjury. Itmayalsobe used toalertagainst unsafe practices.
If you have questions not answered in this manual or require additional copies or the manual
is damaged, please contact your local KUHN dealer or call Kuhn Farm Machinery, Inc. at 1-
800-303-KUHN.

- 3 -
SAFETY RECOMMENDATIONS
WARNING! PROPERANDIMPROPER USES
- DESIGNATED USE OF THE MACHINE -
(READ THIS BEFOREANY USE OF MACHINE)
The FC 4000 G - FC 4000 R - FC 4000 RG Disc Mower Conditioners are not general
purpose mowers. They have been designed for specific and limited usage. Do not use these
machinesfor anythingotherthan the “Properuses”listedbelow.
PROPER USES: The FC 4000 G - FC 4000 R - FC 4000 RG should be used only for the
following purposes: Mowing of improved hay fields and grass silage fields for the purpose of
harvestingfodderforfeeding livestock. These fields must befreeofobstacles(such as metal
casings,wire,twine, machine parts,exposedorburied rocks, etc.).
Themanufactureris not responsibleforanydamage resulting frommachineusageother than
thosespecifiedby the manufacturer. Anyuseother than the designatedoperationis at thefull
riskandresponsibility of the ownerandoperator.
Designateduseof the machine alsomeans:
-Followingoperation, maintenanceandrepair recommendationsgivenby themanufacturer;
-Usingonly genuine spare parts, equipment and accessories as designated by the manufac-
turer.
The FC 4000 G - FC 4000 R - FC 4000 RG mower conditioners must only be operated, main-
tainedorserviced,and transportedby competentand trainedpersons whoare fullyfamiliar with
themachine specifications,operationand maintenance,whohave readthismanual infull(and
all other necessary documents), who have been authorized to do so by the machine’s owner,
andwhoare awareofany dangerinvolved.
Theoperatormustimperativelyrespectallcurrentandapplicable lawsand regulationsconcern-
ing: -Accidentprevention,
-Work safety,
-Transportationof themachine,to includemotorvehicle laws.
Allinformationlisted onsafetydecalsaffixed onthemachine must bestrictlyobserved.
Themanufacturer isnotresponsible foranydamage resultingfrommachine modificationscar-
riedoutby themachineowner oroperatororby anyotherparty withoutpreviouswritten agree-
mentfromthemanufacturer.

- 4 -
SAFETY RECOMMENDATIONS
IMPROPER USES: The FC 4000 G - FC 4000 R - FC 4000 RG must not be used for the
following:
1. DO NOT USE the mower to cut roadsides, ditches, parks, and banks.
2. DO NOT USE themowertocutany unimprovedfields orfieldswithobstacles(suchasmetal
casings,wire,twine machine parts, exposedorburiedrocks, etc.).
3. DO NOT USE the mower to cut trees or hedges.
4. DO NOT USE themowertocut anything while thesafetycovers,shieldsand other compo-
nentsare removedfromthe machine.
5. DO NOT USE themowerto cutanythingwithout thecutterbarin contactwiththe ground.
6. DO NOT OPERATE themoweratunsafe speeds or where control ofthetractorandimple-
mentmay belost.
WARNING! Any improper usage may result in personal injury, death, property damage and
other losses.Any use of the machine for anything other than proper usage is solely at the risk
and responsibility of the operator. The manufacturer is not responsible for any damages or
injuriesresulting fromanyimproper uses.
THESE WARNINGS ARE FOR YOUR PROTECTION - PLEASE FOLLOW THEM!

- 5 -
GENERALSAFETYRECOMMENDATIONS
Beforeoperatingthe machine, alwaysensurethat tractor andmachinearein accordance with
worksafetyand motorvehiclelaws andregulations.
BASIC PRINCIPLES
1. In addition to the recommendations given in this manual, legislation on work safety and
accidentpreventionmust alwaysberespected.
2. Decalsare affixedonthemachine, specifying safetyandother recommendations inorder
topreventaccidents.
3. Beforetravellingonpublicroads,theoperatormustensurethatthemachineconforms toall
applicableroadtraffic laws andregulations.
4. Before starting work or transportation, the operator must be familiar with all machine and
tractorcontrols, handlingdevicesand theirfunctions.
5. Donot wearlooseclothing, etc. thatcouldbecome caught upinmoving elements.
6. Usea tractor equippedwithenclosedcabwith a R.O.P.S.
7. Beforestartingupthemachineandbeginningwork,checkthesurroundingarea(bewareof
children!). Makesurethereissufficientvisibility. Keep all people and animals away from
thedanger zoneofthe machine.
8. Carryingpeople onthemachine whenworking,orduring transport,isstrictly forbidden.
9. Machinemust onlybeattached totractorusingmeansprovided andinaccordance withall
currentapplicablesafety standards,lawsand regulations.
10. Whenattachingorremovingthemachinetoorfrom thetractor,placethe parkingstandinto
theproperposition.
11. Specialcare shouldbetakenwhenattachingorremoving themachinetoorfromthetractor.
12. Before attaching the machine, make sure that the maximum permitted axle weights and
grossweightof the tractor/machinecombinationare not exceeded.
13. Donotexceed the maximumlengthandwidth requirements permittedbyroad traffic laws
andregulations.
14. Donotsurpass themaximumtransport widthauthorizedby roadtrafficregulations.
SAFETY RECOMMENDATIONS

- 6 -
15. Before transportingthemachineonpublicroads,ensure thatalllegallyrequiredguardsand
indicators(lights,reflectors...) are in placeandingood operation.
16. Alloperating controls(cords,cables, rods...)mustbepositionedsothattheycannotbeset
offaccidentally, risking accidentordamage.
17. Beforetransportonpublicroads, locatethe machineinto itstransportpositionasinstructed
inthisoperator’smanual.
18. Neverleavethe tractorseatwhilethe machineisoperating.
19. Drive speed must be adapted to ground conditions as well as roads and paths. Always
avoidabruptchanges of direction.
20. Precisionsteering,tractor adherence,roadholding and efficientbrakingare influencedby
anumber offactorssuchas,but notlimitedtothetype ofimplement, weight,ballastoffront
axle,groundorroad conditions, etc. It is thereforeofutmostimportanceto be cautious in
everygiven situation.
21. Beparticularlycautiouswhenturningcorners,payingattentiontomachineoverhang,length,
heightand weight.
22. Beforeoperatingthe machine,ensurethat allsafetyguards are firmlyinplace andingood
condition. Ifwornor damaged, replaceimmediately.
23. Beforeoperating themachine,checktightnessof allnutsandbolts,particularly onwearing
partsfixingelements (suchasblades, tines, spades...). Retightenifnecessary.
24. Keepclearofthemachineoperatingarea.
25. WARNING! Dangerofcrushingandshearingcanexistwhencomponentsareoperatedby
hydrauliccontrols.
26. Beforeleaving thetractoror beforeadjusting,or servicingthemachine,turnoff theengine,
removeignitionkey and waituntilallmoving parts havecometoa complete stop.
27. Do not stand between the tractor and the machine unless the parking brake is engaged
and/orchocks havebeenplacedunder thewheels.
28. Beforeanyadjustments, maintenance or repairsarecarriedout, ensure that themachine
cannotbestartedupaccidentally.
SAFETY RECOMMENDATIONS

- 7 -
ATTACHMENT
1. Whenattachingorremovingthe machinetoorfromthetractor,makesure thatitcannotmove
accidentally.(Putchocksunderthe wheels).
2. When attaching the machine to tractor lift linkage, ensure that diameter of link pins corre-
spondstodiameterof ball joints.
3. WARNING! Danger of crushing and shearing can exist in the lifting zone of the tractor lift
linkage!
4. Donot standbetweenthetractor and themachinewhenoperating the outercontrollever of
thelift mechanism.
5. Make sure that the weight applied to the tractor’s lift arms does not go over the maximum
weightindicated bythemanufacturer.
6. Make sure flexibility between tractor lift arms and machine draw bar is sufficient, but not
excessive.
7. Thetractor lift arms shouldbestabilizedby the linkage to avoidliftarmside to side shifting.
8. Alwaysensure that themachineandtractor combination is stableandsafewhen operating
or transporting the machine on sloping or bumpy fields. This is especially important when
usinganarrow wheeltracktractor,alighttractor,etc.
POWER TAKE-OFF
1. Onlyuse PTOshaftsupplied withthemachine orrecommendedbythemanufacturer.
2. PTOguards must alwaysbeinplaceand in good condition.
3. Checkfor correctPTOoverlapwhen atworkand in transport.
4. Before attaching or removing the PTO shaft, disengage PTO drive, turn off engine and re-
moveignitionkey
5. Ifa primary PTO shaft is equipped with a slip clutch or a freewheel,thesemustbefittedon
themachine PTO.
6. Ensurethat PTOshaftisalways correctlyfittedand locked intoplace.
7. Makesure guards arecorrectlyin place andsecuredwiththe safety chainsprovided.
SAFETY RECOMMENDATIONS

- 8 -
8. Beforeengaging PTO,ensurethatPTO speed anddirectionof rotation areinaccordance
withmanufacturer’srecommendations.
9. Beforeengaging PTO, keepallpeopleand animals clear fromthemachine.
10. NeverengagePTO drivewhentractor engineisturned off.
11. NeversurpassPTOanglerecommended bythemanufacturer.
12. Warning! Rotatingelementscancontinue turning momentarilyafterPTOis disengaged.
Keepclearuntil all rotatingelementsare at astandstill.
13. Whenremovingthe machine,locatePTO shaftonthe supportsprovided.
14. Fitsafetycap on tractorPTO.
15. Replaceanyworn or damagedPTOguardsimmediately.
TIRES AND WHEELS
1. Before any work is performed on the wheels, ensure that the machine rests on the ground
andisperfectly stablesothatit cannotmoveaccidentally(put chocksinplace).
2. Assembly, disassemblyandrepairofwheels andtires mustonlybecarriedoutbycompetent
trainedpersonsusing proper toolsandequipment.
3. Checktire pressureregularly! Respectmanufacturer’srecommendationsontire pressure.
4. It is possible and recommended to inflate wheels with water and an alkaline solution when
workingon hillyground(particularlyforstandard hitchmodels).
HYDRAULIC SYSTEM
1. WARNING! Hydraulic system is under pressure (maximum working pressure : 200 bars /
2900psi). Any liquidunderpressure (particularlyoil from hydraulics)canpenetrate the skin
andcause severeinjury. If injured,seeadoctorimmediately,therecould bedangerof infec-
tion.
2. Whenfitting hydraulicmotorsorcylinders,ensure thatall connectionsaremadecorrectly, as
permanufacturer’sinstructions.
3. Before connecting hoses to the tractor hydraulics, ensure that tractor and machine circuits
arenot underpressure.
SAFETY RECOMMENDATIONS