KUHN FC244R User manual

Original instructions
KN330CGB_A
Read carefully before starting the machine
Operator's manual
Mower conditioner
---A1026-20C00001 > ---A1026-20C99999
FC244R / FC244R HD
KN330CGB_A - English - 06-2019
*KN330CGB_A*

1. - Dear Owner
FC244R / FC244R HD
3
KN330CGB_A
Mower conditioner
1. Dear Owner
In buying a Kuhn machine you have chosen wisely. Into it have gone years of thought, research and
improvement. You will find, as have thousands of owners all over the world, that you have the best that
engineering skill and actual field testing can produce. You have purchased a dependable machine, but only
through proper care and operation can you expect to receive the performance and long service built into it.
This manual contains all the necessary information for you to receive full efficiency from your machine. The
performance you get from this machine is largely dependent on how well you read and understand this
manual and apply this knowledge. Please DO NOT ASSUME YOU KNOW HOW TO OPERATE AND
MAINTAIN YOUR MACHINE before reading this manual carefully. KEEP THIS MANUAL AVAILABLE FOR
REFERENCE. Pass it on to the next owner if you re-sell the machine.
Your KUHN dealer can offer a complete line of genuine KUHN service parts. These parts are manufactured
andcarefully inspectedinthe samefactorythat buildsthe machine to assure high quality and accurate fitting
of any necessary replacements.
About improvements
We are continually striving to improve our products. We therefore reserve the right to make improvements
or changes when it becomes practical to do so, without incurring any obligations to make changes or
additions to the equipment sold previously.
Wear parts
Wearing parts fitted on our machines have been tested in very different situations to optimize their service
life. Nevertheless, the service life depends highly on the conditions of use (products to handle, soil, weather
conditions, etc...).
Document illustrations
The illustrations in this manual may be based on one type of machine only. However, all instructions apply
to all machines covered in this manual.
Copyright 2019 KUHN

FC244R / FC244R HD
42. - Contents
KN330CGB_A
Mower conditioner
2. Contents
1. Dear Owner .....................................................................................................................3
2. Contents..........................................................................................................................4
3. Identification of the machine.........................................................................................8
3.1 Front view ........................................................................................................................................ 8
3.2 Rear view......................................................................................................................................... 8
3.3 Identification of the machine............................................................................................................ 9
3.3.1 Location of the plates .........................................................................................................9
3.3.2 Description.......................................................................................................................... 9
3.4 Optional equipment.........................................................................................................................11
4. Safety.............................................................................................................................12
4.1 Description of symbols used in this document...............................................................................12
4.2 Safety instructions ......................................................................................................................... 13
4.2.1 Introduction.......................................................................................................................13
4.2.2 Read and follow the safety instructions............................................................................ 13
4.2.3 Precautions to be taken before carrying out any operations on the machine................... 13
4.2.4 Precautions to take before using the machine ................................................................. 14
4.2.5 Precautions when driving ................................................................................................. 15
4.2.6 Precautions when driving on public roads........................................................................15
4.2.7 Maximum speed...............................................................................................................19
4.2.8 Precautions when coupling...............................................................................................19
4.2.9 Hydraulic circuit................................................................................................................ 20
4.2.10 PTO shaft.......................................................................................................................... 21
4.2.11 Precautions during manoeuvres....................................................................................... 23
4.2.12 Remote controlled components........................................................................................ 23
4.2.13 Hydro-pneumatic accumulator.......................................................................................... 23
4.2.14 Safety decals....................................................................................................................24
4.2.15 Waste disposal .................................................................................................................24
4.2.16 Precautions for maintenance and repair work.................................................................. 25
4.2.19 Precautions to take before using the parking stands........................................................27

2. - Contents
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4.3 Location and description of safety decals on the machine............................................................ 28
4.3.1 Location of safety decals..................................................................................................28
4.3.2 Description of safety decals ............................................................................................. 29
4.4 Road safety equipment and recommendations............................................................................. 32
4.4.1 Specific instructions.......................................................................................................... 34
4.5 Likely critical failures...................................................................................................................... 34
4.6 Incorrect use of the machine by the user ...................................................................................... 35
4.7 Limit state criteria........................................................................................................................... 35
5. Machine specifications................................................................................................ 36
5.1 Description and glossary ............................................................................................................... 36
5.1.1 Designated use of the machine........................................................................................ 37
5.2 Technical specifications................................................................................................................. 37
5.2.1 Designated parameters.................................................................................................... 37
5.3 Required equipment...................................................................................................................... 38
5.3.1 Cutter bar ......................................................................................................................... 38
5.3.2 Hydraulic adjustment........................................................................................................ 39
5.4 Sound levels.................................................................................................................................. 39
6. Putting into service...................................................................................................... 40
6.1 Description of control elements ..................................................................................................... 40
6.2 Coupling and uncoupling............................................................................................................... 41
6.2.1 Description of coupling elements ..................................................................................... 42
6.2.2 Preparing the tractor......................................................................................................... 42
6.2.3 Preparing the machine..................................................................................................... 44
6.2.4 Coupling the machine.......................................................................................................47
6.2.5 Hydraulic connections......................................................................................................48
6.2.6 Electrical connections....................................................................................................... 49
6.2.7 Primary PTO shaft............................................................................................................ 49
6.2.8 Intermediate PTO shaft .................................................................................................... 51
6.2.9 Adjusting the machine......................................................................................................53
6.2.10 Uncoupling the machine................................................................................................... 54
7. Instructions for transport............................................................................................ 56
7.1 Putting the machine into transport position ................................................................................... 56
7.2 Conformity with the road regulations............................................................................................. 58
7.3 Machine transport using transport means ..................................................................................... 58

FC244R / FC244R HD
62. - Contents
KN330CGB_A
Mower conditioner
8. Instructions for work....................................................................................................59
8.1 Putting the machine into work position .......................................................................................... 59
8.2 Adjustments in working position.....................................................................................................61
8.2.1 Cutting height ...................................................................................................................61
8.2.2 Ground pressure...............................................................................................................62
8.2.3 Conditioning intensity .......................................................................................................66
8.2.4 Swath width adjustment....................................................................................................67
8.3 Machine use .................................................................................................................................. 67
8.3.1 Drive speed ......................................................................................................................68
9. Optional equipment......................................................................................................69
9.1 Raised skid shoes.......................................................................................................................... 69
9.2 Swath shield extensions ................................................................................................................ 69
9.3 Flow limiter..................................................................................................................................... 70
9.4 Lateral signalling equipment.......................................................................................................... 70
9.5 Female coupler.............................................................................................................................. 71
9.6 USA signalling equipment.............................................................................................................. 71
9.6.1 Coupling and uncoupling..................................................................................................71
9.7 Chain stroke limiter........................................................................................................................ 72
10. Maintenance and storage ............................................................................................74
10.1 Frequency chart............................................................................................................................. 74
10.2 Cleaning the machine.................................................................................................................... 75
10.3 Lubrication .....................................................................................................................................76
10.3.1 PTO shaft.......................................................................................................................... 76
10.3.2 Oil change ........................................................................................................................ 78
10.3.3 Lubrication........................................................................................................................ 81
10.3.4 Greasing........................................................................................................................... 82
10.4 Maintenance .................................................................................................................................. 85
10.4.1 Hydro-pneumatic accumulator.......................................................................................... 85
10.4.2 Transport stop...................................................................................................................86
10.4.3 Checking the roller parallelism and gap ........................................................................... 87
10.4.4 Drive chain tension...........................................................................................................88
10.4.5 Chain replacement and roller synchronization ................................................................. 90
10.4.6 Belt tension.......................................................................................................................92
10.4.7 Replacing the belts...........................................................................................................93
10.4.8 Checking cutterbar oil level ..............................................................................................95
10.4.9 Inspection of knives and securing elements..................................................................... 96
10.4.10 Outer and inner cones....................................................................................................106
10.4.11 Intermediate PTO shaft...................................................................................................107

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10.5 Storage.........................................................................................................................................110
10.5.1 At the end of each season...............................................................................................110
10.5.2 At the start of each season..............................................................................................111
10.5.3 Storage............................................................................................................................113
10.6 Dismantling and scrapping of the machine...................................................................................113
11. Troubleshooting guide.............................................................................................. 114
12. Appendix.....................................................................................................................120
12.1 Calculating the load on an axle ................................................................................................... 120
13. Limited Warranty........................................................................................................ 128

FC244R / FC244R HD
83. - Identification of the machine
KN330CGB_A
Mower conditioner
3. Identification of the machine
3.1 Front view
3.2 Rear view

3. - Identification of the machine
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3.3 Identification of the machine
- Do not remove the manufacturer,
homologation and marking plates attached
to the machine.
3.3.1 Location of the plates
- Please write below the type and serial number of
the machine.
• Serial Number:
- This information is to be given to the Kuhn
authorized dealer for any spare parts order or
warranty claim.
3.3.2 Description
Model identification plate
1: Manufacturer name and address
3: Brand
4: KUHN logo
5: Description of the machine
7: Model
9a: Machine serial number
9b: Barcode (Machine serial number)
12: Weight empty (Minimum/Maximum)
18: Data matrix
19: Plate reference
27: Place of manufacture
28: Manufactured by... for...
34: Special operation
9: Serial Nr. 34: Ex
5: Machine
7: Model
09993000
3: Brand
kg
kg
12: Unladen Mass min/Max
3: 商 Brand
9: 机架号 Serial Nr. 34: Ex
5: 机器描述 Machine
7: 型号 Model
kg
12: 卸重量最小/最大Unladen Mass min/max kg
1
34
18
19
3
9a
5
7
12
28
27
9b
4

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10 3. - Identification of the machine
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Mower conditioner
Certification plate (CE)
For machines aimed at countries which are
members of the European Union (EC marking).
4: KUHN logo
7: Model
9: Machine serial number
19: Plate reference
23: Logo CE
24: Manufacturing year
26: Model year
54: Data matrix
Certification plate (EAC)
For machines aimed at countries member of the
Eurasian customs union (EAC marking).
4: KUHN logo
7: Model
9: Machine serial number
19: Plate reference
23: Logo EAC
25: Manufacturing year
26: Model year
54: Data matrix
Importer plate (BRASIL)
For machines to be sent to Brazil.
1: Manufacturer name and address
4: KUHN logo
7: Model
9: Machine serial number
19: Plate reference
24: Manufacturing year
54: Data matrix
24: Year of Construction
26: Model Year
7: Model
9: Serial Nr.
23
54
4
19
7
9
24
26
25: Month-Year of Construction
26: Model Year
7: Model
9: Serial Nr.
23
54
4
26
25
7
9
19
0000
24: Year of Construction
09993700
MODEL1234
7: Model
19
18 4
1
24
7

3. - Identification of the machine
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KN330CGB_A
Mower conditioner
3.4 Optional equipment
- Tick box corresponding to the equipment fitted on
your machine:
Raised skid shoes 120 mm (4.7’’).
Swath shield extensions.
Shut off valve.
Lateral signalling equipment (For: France, Belgium).
Female coupler.
USA signalling equipment.
Chain stroke limiter.

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12 4. - Safety
KN330CGB_A
Mower conditioner
4. Safety
4.1 Description of symbols used in
this document
This symbol indicates a potentially hazardous
situation that if not avoided, could result in serious
bodily injury.
This symbol is used to identify special instructions or
procedures which, if not followed strictly, could result
in machinery damage.
This symbol is used to communicate technical
information of particular interest.

4. - Safety
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4.2 Safety instructions
4.2.1 Introduction
The machine must only be operated, maintained and repaired by competent persons who are familiar with
machines' specifications and operation and aware of safety regulations for preventing accidents.
The operator must imperatively respect safety instructions in this manual and in the warnings posted on the
machine. The operator is also obliged to respect current legislation concerning accident prevention, work
safety and public traffic circulation.
Designated use of the machine also means following operation, maintenance and repair recommendations
given by the manufacturer, and using only genuine spare parts, equipment and accessories, as
recommended by the manufacturer.
The manufacturer is not held liable for any damage resulting from machine applications other than those
specified by the manufacturer. Any use other than the designated operation is at the risk and responsibility
of the operator.
The manufacturer is not held liable for any damage or accident resulting from machine modifications carried
out by the operator himself or by a third party without previous written agreement from the manufacturer.
4.2.2 Read and follow the safety instructions
- Before using the machine, carefully read all the
safety instructions in this manual and the warnings
placed on the machine.
- Before starting work, the operator must be familiar
with all machine controls, handling devices and
their functions. It is too late to learn once work has
been started!
- Never let anyone operate the machine who is not
trained to do so.
- Should you have any difficulties in understanding
any parts of this manual, please contact your
KUHN dealer.
4.2.3 Precautions to be taken before carrying
out any operations on the machine
- Before leaving the tractor or before adjusting,
maintaining or repairing the machine, disengage
the PTO drive, turn off the engine, remove ignition
key and wait until all moving parts have come to a
complete stop and apply park brake.

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14 4. - Safety
KN330CGB_A
Mower conditioner
4.2.4 Precautions to take before using the
machine
Do not wear loose clothing which could become
caught up in moving parts.
Wear the appropriate protective clothing for the work
in hand (gloves, shoes, goggles, helmet, ear
defenders, etc.).
Ensure that all operating controls (ropes, cables,
rods, etc) are placed so as they cannot be operated
unintentionally and cause damage or injury.
Before operating the machine, check tightness of
nuts and bolts, particularly on fixing elements (tines,
forks, blades, knives, etc). Retighten if necessary.
Before operating the machine, ensure that all the
safety guards are firmly in place and in good
condition. Immediately replace any worn or
damaged guard.

4. - Safety
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4.2.5 Precautions when driving
Tractor handling, stability, performance and braking
efficiency are all affected by weight distribution,
trailed or mounted implements, additional ballast
and driving conditions. It is therefore of great
importance that the operator exercises caution in
every given situation.
Groundspeed must be adapted to ground conditions
as well as to roads and paths. Always avoid abrupt
changes of direction.
Be particularly cautious when turning corners,
paying attention to machine overhang, length, height
and weight.
Never use a narrow track tractor on very uneven or
steeply sloping ground.
Never leave the tractor seat while the machine is
operating.
Carrying people or animals on the machine when
working or in transport is strictly forbidden.
4.2.6 Precautions when driving on public
roads
Dimensions
- Depending on the dimensions of the machine,
contact the relevant authorities to ensure that it
can be legally transported on public roads.
- If the machine is over the maximum legal size,
follow the local regulations for special
transportation of oversize equipment.
Transport position
- Before transporting the machine on public roads,
place the machine into its transport position,
according to the instructions in this manual.

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KN330CGB_A
Mower conditioner
Lights and indicators
Gross weight and weight per axle
Before transporting the machine on public roads,
ensure that all legally required lightings and
signallings are in place.
Ensure that lightings and signallings are clean and in
good working order. Replace any missing or broken
equipment.
Always obey current regulations for driving
on roads.
The drawings are not legally binding, their only aim is to illustrate the method to use.
Prior to driving on public roads, check that all criteria are met to be in conformity with the
countrie's regulations:
• When coupling a tool to the front and/or rear 3-point lift linkage, the maximum authorized
payload must not be exceeded.
• When coupling tools to the front and/or rear 3-point lift linkages, the maximum load on
tractor's tires must not be exceeded.
• The load on the tractor front axle must always represent 20 % of the tractor unladen weight.
For machines with hoppers or tanks:
- If the total unit weight exceeds the tractor Gross Combined Weight Rating in accordance with
the countrie's legislation, empty the hopper to travel on public roads.
- In any case, we recommend to travel on public roads with empty hoppers and tanks.

4. - Safety
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Description of symbols
How to proceed:
Stage 1:
Description Units Description
T kg Tractor unladen weight
PTAC kg Gross Combined Weight Rating
T1 kg Unladen load on tractor front axle
T2 kg Empty load on tractor rear axle
t kg Axle loads (Tractor + machine)
t1 kg Load on front axle (Tractor + machine)
t2 kg Load on rear axle (Tractor + machine)
t1 max kg Maximum load authorized on the tractor front axle according to the tires
t2 max kg Maximum load authorized on the tractor rear axle according to the tires
M1 kg Total weight of front tool or front ballast
To measure:
- Tractor tare (T).
T = _____kg
T = ________ kg

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18 4. - Safety
KN330CGB_A
Mower conditioner
Stage 2:
Stage 3:
- Couple the machine to the tractor.
To measure:
- Load on front axle (t1):
• Tractor + machine (transport position).
To do:
- If the front axle load (t1) is below 20% of the tractor
tare (T), add ballast weights (M1) to exceed the
minimum load on the front axle.
Example:
• (T) = 7500 kg (16535 lb).
• The front axle load must be of minimum 1500 kg
(3300 lb).(20% of T).
• (t1) = 700 kg (1545 lb).
• 700 kg (1545 lb) < 1500 kg (3300 lb).
• Add ballast weights until the minimum front axle
load is exceeded.
• Repeat checking procedure.
t1 < 20% T
t1 < 20% T
t1
t1 ≥
20% T
20% T
t1 = _____kg
t1 = ________ kg
To measure:
- Total weight (t):
• Tractor + machine (transport position).
• Ballast weights.
Checking:
- To go to the next stage:
• Check in the tractor's operator's manual that the
value measured is below the tractor's Gross
Combined Weight Rating.
To do:
- If t < PTAC go to the next stage.
- If the total unit weight exceeds the tractor Gross
Combined Weight Rating in accordance with the
countrie's legislation, empty the hopper to travel on
public roads.
- Repeat checking procedure.
Example:
• (t) = 10000 kg (22046 lb).
• PTAC = 13000 kg (28660 lb).
• t < PTAC : Go to the next stage.
kgkg
t = _____kg
t = ________ kg

4. - Safety
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KN330CGB_A
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Stage 4:
To measure:
- Load on rear axle (t2):
• Tractor + machine (transport position).
• Ballast weights.
Checking:
- Check in the tractor's operator's manual that the
value measured is below the maximum allowed
tractor rear axle load.
- Check that tyre and rim specifiations are in
conformity with the requirements of the tractor
manufacturer.
Example:
• Load on rear axle (t2) = 8500 kg (18740 lb).
• Check in the tractor's operator's manual that the
value measured is below the maximum allowed
tractor rear axle load.
• Check that tyre and rim specifiations are in
conformity with the requirements of the tractor
manufacturer.
4.2.7 Maximum speed
- Always keep to the legal speed limit for driving a
tractor-machine assembly on public roads.
4.2.8 Precautions when coupling
- Before attaching the machine, make sure that it
cannot accidentally start moving (chock the
wheels) and that the parking stand is in the right
position.
- The machine must only be attached to the hitch
points provided for this purpose.
- Do not stand between the machine lower hitching
points or between the tractor lower hitching points
during coupling maneuvers.
- Never stand between the tractor and the machine
when operating the three point linkage.
- Do not stand between the machine and the tractor
or on the machine without having first applied the
tractor parking brake and placed the gearbox in the
neutral position.
kgkg
t2 = _____kg
t2 > t2 max
t2 > t2 max
t2
t2 ≤
t2 max
t2 max
t2 = ________ kg

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20 4. - Safety
KN330CGB_A
Mower conditioner
4.2.9 Hydraulic circuit
Caution! The hydraulic circuit is under high pressure.
Maximum pressure at work: 200 bar (2901 psi).
Before connecting hoses to the tractor hydraulics,
ensure that tractor and machine circuits are not
under pressure. Before disconnecting a hose,
depressurize the hydraulic circuit.
To avoid making incorrect connections, mark
hydraulic couplers and corresponding hoses with
colors. WARNING! Functions could be reversed (for
example: lift/lower) and cause accidents.
Regularly make visual inspection to check if
hydraulic hoses are damaged or worn. In case of
normal wear, the hydraulic hoses must be replaced
every 5 years. Damaged or worn hoses must
immediately be replaced. When replacing the
hydraulic hoses, only use hoses with the
specification recommended by the manufacturer of
the machine.
To locate a leak, use appropriate means. Protect
body and hands from liquid under pressure.
Any liquid under pressure (particularly oil from
hydraulics) can penetrate the skin and cause severe
injury. If injured, see a doctor immediately, there
could be danger of infection.
Before any adjustments, maintenance or repairs are
carried out, lower the machine to the ground,
depressurize the hydraulics, turn off the engine,
remove ignition key and wait until all moving parts
have come to a complete stop.