KUHN HR4004D User manual

Original instructions
KN208CGB A
OPERATOR'S MANUAL
Power harrows
HR4004D - 4504D
KN208CGB A
- English - 11-2012

Dear Owner
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$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 and
carefully inspected in the same factory that builds the machine to assure high quality and accurate fitting of any
necessary replacements.
About improvements
We are continually striving to improve our products. It therefore reserves 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...).
Designated use of the machine
HR4004D / HR4504D power harrows must only be used for work for which they have been designed: Seedbed
preparation on ploughed ground or in min-tilled ground with or without simultaneous seeding.
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 2012 KUHN S.A.

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Contents
$Contents
Dear Owner.....................................................................................................................1
Contents..........................................................................................................................2
Identification of the machine.........................................................................................4
Front view..........................................................................................................................................4
Rear view...........................................................................................................................................4
Model identification plate ................................................................................................................5
Optional equipment..........................................................................................................................6
Safety...............................................................................................................................8
Description of symbols used in this document.............................................................................8
Safety instructions...........................................................................................................................9
Location and description of safety decals on the machine .......................................................19
Road safety equipment and recommendations...........................................................................21
Machine specifications................................................................................................22
Description and glossary...............................................................................................................22
Technical specifications................................................................................................................23
Required equipment.......................................................................................................................24
Sound levels ...................................................................................................................................27
Putting into service......................................................................................................28
Coupling and uncoupling..............................................................................................................28
Instructions for transport............................................................................................44
Putting the machine into transport position................................................................................44
Conformity with the road regulations...........................................................................................44

Contents
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Instructions for work................................................................................................... 45
Putting the machine into work position.......................................................................................45
Adjustments in working position..................................................................................................45
Machine use....................................................................................................................................46
Optional equipment.....................................................................................................48
Sets of gearwheels.........................................................................................................................48
Standard linkage ............................................................................................................................50
Hydraulic lift linkage......................................................................................................................51
Hydraulic lift linkage stroke limiters.............................................................................................56
High capacity hydraulic lift linkage ..............................................................................................57
Track eradicators............................................................................................................................62
Front or rear levelling bar..............................................................................................................64
Front semi-automatic linkage .......................................................................................................65
Adaptation parts for VENTA LC.....................................................................................................66
Adaptation parts for VENTA AL and VENTA TI............................................................................66
Adaptation parts for INTEGRA......................................................................................................67
Lengthened coupling yokes..........................................................................................................67
Maintenance and storage............................................................................................ 68
Frequency chart .............................................................................................................................68
Cleaning the machine....................................................................................................................69
Lubrication......................................................................................................................................71
Maintenance....................................................................................................................................74
Storage............................................................................................................................................82
Troubleshooting guide................................................................................................83
Appendix ...................................................................................................................... 85
Calculating the load on an axle.....................................................................................................85
Limited warranty.......................................................................................................... 91

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Identification of the machine
$Identification of the machine
1. Front view
2. Rear view

Identification of the machine
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3. Model identification plate
Please write below the type and serial number of the
machine. This information is to be indicated to the dealer
for all spare parts orders.
HR4004D / HR4504D
Type: HR4004D / HR4504D
Serial no.:
TYPE
MASSE kg
KUHN S.A.
67700 SAVERNE - FRANCE
N°
MADE IN FRANCE

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Identification of the machine
4. Optional equipment
Tick box corresponding to the equipment fitted on your
machine:
HR4004D / HR4504D
Set of gearwheels (30 and 35 teeth matching gears).
Set of gearwheels (27 and 38 teeth matching gears).
Set of gearwheels (25 and 40 teeth matching gears).
Set of gearwheels (33 and 32 teeth matching gears).
Standard linkage.
Hydraulic lift linkage.
Hydraulic lift linkage stroke limiters.
High capacity hydraulic lift linkage.
2 track eradicators with traction bolt overload mechanism.
2 track eradicators with spring overload mechanism.
Semi-automatic front linkage category 2.
Semi-automatic front linkage category 3.
Adaptation parts for VENTA LC.
Floating adaptation parts for adaptation of VENTA AL and VENTA TI roller.
Rigid adaptation parts for adaptation of VENTA AL and VENTA TI.
Floating adaptation parts for INTEGRA roller (Packer PK2 roller and Maxipacker roller).
Floating adaptation parts for INTEGRA roller (Packliner roller).
Rigid adaptation parts for INTEGRA.
Lengthened coupling yokes.

Identification of the machine
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HR4004D
HR4504D
Track eradicator mounting yokes.
Front or rear levelling bar.
Track eradicator mounting yokes.
Front or rear levelling bar.

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Safety
$Safety
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.

Safety
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2. Safety instructions
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 certain
parts in this manual, please contact your KUHN dealer.
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.
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 operatoris also obligedto 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.

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Safety
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.
Precautions when driving
Tractor handling, stability, performance and braking
efficiency are all affected by weight distribution, trailedor
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.

Safety
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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.
Lights and indicators
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.
Gross weight and weight per axle
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.

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Safety
Description of symbols
Stage 1:
To measure:
- Tractor tare (T).
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.
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
T = _____kg

Safety
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Stage 2:
- 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.
Stage 3:
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.
Example:
• (t) = 10000 kg (24250 lb)
•PTAC = 13000 kg .
• t < PTAC : Go to the next stage.
t1 = _____kg
t1 < 20% Tt1 < 20% T
t1t1 ≥20% T20% T
kgkg
t = _____kg

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Safety
Stage 4:
To measure:
- Load on rear axle (t2):
• Tractor + machine (transport position).
• Ballast weights.
Checking:
- Check in the tractor'soperator'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.
Maximum speed
Always keep to the legal speed limit for driving a tractor-
machine assembly on public roads.
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.
Never stand between the tractor and the machine when
operating the three point linkage.
Do not stand between the tractor and the machine
without ensuring that the parking brake is applied.
kgkg
t2 = _____kg
t2 > t2 maxt2 > t2 max
t2t2 ≤t2 maxt2 max

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PTO shaft
Do not wear loose clothing that could be caught in the
rotating PTO shaft.
Before attaching or removing a PTO shaft, or before
doing any work on the machine, disengage the PTO
drive, turn off the engine, remove ignition key and wait
for all moving parts have come to a complete stop.
If the primary PTO shaft is equipped with a torque limiter
or a free wheel, these must be fitted on the machine
side.
Ensure that the PTO shaft is always correctly fitted and
locked into place.
Before connecting the PTO shaft, ensure that the PTO
speed (rotational frequency) and direction of rotation are
in line with the machine manufacturer's
recommendations.
Before engaging the PTO drive, make sure all people
and animals are clear from the machine. Never engage
the PTO drive when the tractor engine is stopped.
Do not install any adapter device that results in a portion
of the tractor PTO stub, the rotating PTO shaft, or the
adapter to be unguarded. The tractor master shield shall
overlap the end of the splined shaft and the added
adaptor device as outlined in the table.
When uncoupling the machine, rest the PTO shaft on the
support specially provided, and replace protective shield
on the PTO stub of the tractor.
Read and follow theinstructions in the operator's manual
provided with the PTO shaft.
Use only PTO shafts supplied with the machine or recommended by the machine manufacturer.
The protective shield of the tractor PTO stub, the PTO shaft guards and the protective shield of the machine
input shaft must always be in place and in good condition.
Make sure that the PTO shaft guards are secured with the safety chains provided. Check that the PTO shaft
guard can turn freely a full rotation independent of the shaft.
Any worn or damaged guards must be replaced immediately. A worn guard or an unprotected PTO shaft can
cause a serious or even a lethal accident.
A
PTO type Diameter X splines
A
±5 mm (0.20’’)
135 mm
(1.378’’) 685 mm (3.35’’)
235 mm
(1.378’’) 21 85 mm (3.35’’)
345 mm
(1.772’’) 20 100 mm (4.00’’)

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Safety
Precautions during manoeuvres
When moving the machine from the transport position to
the working position and vice versa, make sure that
nobody is within the machine pivoting area.
Remote controlled components
Danger of crushing and shearing can exist when
components are operated by hydraulic or pneumatic
controls. Keep away from these danger zones.
Safety decals
Safety warning decals are placed in pictorial form on
various parts of the machine. They are there to warn you
of potential dangers and to tell you how to avoid
accidents. Always keep the safety decals clean and
readable, and replace them when they are worn,
damaged, missing or illegible.

Safety
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Waste disposal
Respect the environment! Never spill pollutants (oil,
grease, filters, etc.) on the ground, never pour them
down the drain and never discard them in any other
place where they could pollute the environment. Never
throw away or burn a tyre. Always take waste to
specialized recycling or waste disposal centers.
Precautions for maintenance and repair
work
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.
Rest the machine on the ground, release the pressure
from the hydraulic circuit and leave the machine to cool
down.
Make sure that the parts of the machine that need to be
lifted for maintenance or repair work are firmly propped
up.
Before any work is done on the electric circuit or before
any electric welding is carried out on the attached
machine, disconnect the machine from the tractor
electrical circuit. Also disconnect alternator and battery
terminals.
Repairs on elements under pressure or tension (springs,
pressure accumulators, etc.) must only be carried out by
competent persons with regulation equipment.
Wear the appropriate protective clothing for the work in
hand (gloves, shoes, goggles, helmet, ear defenders,
etc.).
Do not solder, weld or use a blow torch near fluids under
pressure or inflammable products.
For your own safety and for correct machine operation,
only use original manufacturer parts.

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Safety
Projection of stones and foreign objects
For driver safety, always use a tractor equipped with a
cab. Never start the machine when there are people
nearby. Even when the machine is used in accordance
with its purpose, objects may be projected. Stones and
other foreign objects projected by the moving parts can
travel a considerable distance. Keep all persons and
animals away from the danger zone.
Precautions for machine use
After each use, check the tools (blades) and their
attachment hardware in accordance with the instructions
given in the present manual.
Check the guards regularly. Immediately replace any
damaged or missing elements.
Make sure all the guards are in place. Keep all persons
and animals away from the danger zone.
Stay a safe distance from the machine when the cutting
tools are in movement.
Never work in reverse.
After disengaging the PTO drive, tools can continue
rotating for some time. Stay away from the machine until
all moving parts have come to a complete standstill.
If an obstacle is hit, disengage the PTO drive, stop the
tractor engine, remove the ignition key and wait for all
moving parts to come to a complete standstill. Check the
entire machine for any damage before resuming work.