KUHN FC4460 TCR User manual

Original instructions
KN342AGB_C
Read carefully before starting the machine
Operator's manual
Mower conditioner
A0001 > A9999
FC4460 TCR/TCS
KN342AGB_C - English - 10-2018
*KN342AGB_C*

1. - Dear Owner
FC4460 TCR/TCS
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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 inspected in the same factory thatbuilds the 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 2018 KUHN

FC4460 TCR/TCS
42. - Contents
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2. Contents
1. Dear Owner .....................................................................................................................3
2. Contents..........................................................................................................................4
3. Identification of the machine.........................................................................................7
3.1 Front view ........................................................................................................................................ 7
3.2 Rear view......................................................................................................................................... 7
3.3 Model identification plate ................................................................................................................. 8
3.4 Optional equipment.......................................................................................................................... 9
4. Safety.............................................................................................................................10
4.1 Description of symbols used in this document...............................................................................10
4.2 Safety instructions ..........................................................................................................................11
4.2.1 Introduction........................................................................................................................11
4.2.2 Read and follow the safety instructions.............................................................................11
4.2.3 Safety decals.....................................................................................................................11
4.2.4 Precautions to be taken before carrying out any operations on the machine................... 12
4.2.5 Precautions when coupling...............................................................................................12
4.2.6 PTO shaft.......................................................................................................................... 12
4.2.7 Hydraulic circuit................................................................................................................ 15
4.2.8 Remote controlled components........................................................................................ 15
4.2.9 Precautions when driving ................................................................................................. 16
4.2.10 Precautions when driving on public roads........................................................................ 16
4.2.11 Maximum speed...............................................................................................................18
4.2.12 Tyres................................................................................................................................. 18
4.2.13 Precautions to take before using the machine ................................................................. 18
4.2.14 Precautions during manoeuvres....................................................................................... 18
4.2.15 Precautions for machine use............................................................................................ 19
4.2.16 Projection of stones and foreign objects........................................................................... 20
4.2.17 Precautions for maintenance and repair work..................................................................21
4.2.18 Waste disposal .................................................................................................................21
4.2.19 Precautions to take before using the parking stands........................................................ 22
4.3 Location and description of safety decals on the machine ............................................................ 23
4.3.1 Location of safety decals..................................................................................................23
4.3.2 Description of safety decals.............................................................................................. 24
4.4 Road safety equipment and recommendations ............................................................................. 25
4.4.1 Tyre pressure....................................................................................................................26
4.5 Likely critical failures...................................................................................................................... 27
4.6 Incorrect use of the machine by the user....................................................................................... 27
4.7 Limit state criteria........................................................................................................................... 27

2. - Contents
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5. Machine specifications................................................................................................ 28
5.1 Description and glossary ............................................................................................................... 28
5.1.1 Designated use of the machine........................................................................................ 31
5.2 Technical specifications................................................................................................................. 31
5.2.1 Designated parameters.................................................................................................... 32
5.3 Required equipment...................................................................................................................... 32
5.3.1 Pto shaft........................................................................................................................... 32
5.4 Sound levels.................................................................................................................................. 32
6. Putting into service...................................................................................................... 33
6.1 Description of control elements ..................................................................................................... 33
6.2 Coupling and uncoupling............................................................................................................... 34
6.2.1 Description of coupling elements ..................................................................................... 34
6.2.2 Preparing the tractor......................................................................................................... 34
6.2.3 Coupling the machine.......................................................................................................35
6.2.4 Hydraulic connections......................................................................................................37
6.2.5 Electrical connections....................................................................................................... 37
6.2.6 Fit the check chains.......................................................................................................... 37
6.2.7 Primary PTO shaft............................................................................................................ 38
6.2.8 Intermediate PTO shaft .................................................................................................... 40
6.2.9 Adjusting the machine......................................................................................................42
7. Instructions for transport............................................................................................ 44
7.1 Transport position.......................................................................................................................... 44
7.2 Putting the machine into transport position ................................................................................... 44
7.3 Conformity with the road regulations............................................................................................. 46
7.4 Machine transport using transport means ..................................................................................... 46
8. Instructions for work................................................................................................... 47
8.1 Putting the machine into work position.......................................................................................... 47
8.2 Adjustments in working position .................................................................................................... 48
8.2.1 Cutting height................................................................................................................... 48
8.2.2 Ground pressure .............................................................................................................. 50
8.2.3 Conditioning intensity....................................................................................................... 51
8.2.4 Checking the roller parallelism and gap........................................................................... 52
8.2.5 Swathing and wide spreading .......................................................................................... 54
8.3 Machine use .................................................................................................................................. 56
8.3.1 Drive speed...................................................................................................................... 57
9. Recommendations for uncoupling............................................................................. 58

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10. Optional equipment......................................................................................................60
10.1 Check chains ................................................................................................................................. 60
10.2 Lifters............................................................................................................................................. 60
10.3 Wide spreading system ................................................................................................................. 61
10.3.1 Instructions for work .........................................................................................................61
10.4 1 3/8 - 21 spline yoke..................................................................................................................... 63
10.5 Outline marker lights......................................................................................................................64
10.6 Female coupler.............................................................................................................................. 64
10.7 Raised skid shoes adjustable in height.......................................................................................... 64
10.7.1 Adjustments......................................................................................................................65
10.8 Swath shield extensions................................................................................................................ 67
11. Maintenance and storage ............................................................................................68
11.1 Frequency chart.............................................................................................................................68
11.2 Cleaning the machine.................................................................................................................... 69
11.3 Lubrication ..................................................................................................................................... 70
11.3.1 PTO shafts........................................................................................................................ 71
11.3.2 Grease..............................................................................................................................74
11.3.3 Draining............................................................................................................................ 75
11.4 Maintenance ..................................................................................................................................80
11.4.1 Checking the oil levels...................................................................................................... 80
11.4.2 Side gearbox filter............................................................................................................. 81
11.4.3 Inspection of knives and securing elements..................................................................... 82
11.4.4 Fitting of the lifters ............................................................................................................92
11.4.5 Ground pressure adjustment system................................................................................ 94
11.4.6 Roller drive ....................................................................................................................... 99
11.5 Storage ........................................................................................................................................ 101
11.5.1 At the end of each season.............................................................................................. 101
11.5.2 At the start of each season............................................................................................. 101
11.5.3 Storage........................................................................................................................... 102
11.6 Dismantling and scrapping of the machine.................................................................................. 102
12. Troubleshooting guide...............................................................................................103
13. Limited Warranty ........................................................................................................105

3. - Identification of the machine
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3. Identification of the machine
3.1 Front view
3.2 Rear view

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83. - Identification of the machine
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3.3 Model identification plate
- Please write below the type and serial number of
the machine. This information is to be given to the
Kuhn authorized dealer for any spare parts order
or warranty claim.
• (1) The manufacturer:
• (2) Type:
• (3) Serial Number:
• (4) Weight:
According to the country of destination,
additional plates can be fitted on the
machine.
For machines aimed at countries which are
members of the European Union (EC marking):
• (5) Manufacturing year:
For machines aimed at countries member of the
Eurasian customs union (EAC marking):
• (6) Model year:
• (7) Manufacturing year:
TYPE
MASSE kg
KUHN S.A.
67700 SAVERNE - FRANCE
N°
MADE IN FRANCE
1
3
2
4
5
09993600
25: Year of Construction
0000
00/0000
26: Model Year
7
6

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3.4 Optional equipment
- Tick box corresponding to the equipment fittedon
your machine:
Check chains.
Lifters.
Wide spreading system.
1 3/8 - 21 spline yoke.
Outline marker lights.
Female coupler.
Raised skid shoes adjustable in height.
Swath shield extensions.

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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.
Thissymbol isused 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 frommachine 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 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 tellyou how to avoid
accidents.
- Always keep the safety decals clean and
readable, and replace them when they are worn,
damaged, missing or illegible.

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4.2.4 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.
4.2.5 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 machine and the
tractor or on the machine without having first
applied the tractor parking brake and placed the
gearbox in the neutral position.
4.2.6 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.

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- 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 to 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 that
there are no people or animals near 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.
A

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PTO type Diameter X splines A ±5 mm (0.20’’)
1 35 mm (1.378’’) 6 85 mm (3.35’’)
236 mm (1.42’’) 885 mm (3.35’’)
3 35 mm (1.378’’) 21 85 mm (3.35’’)
445 mm (1.772’’) 20 100 mm (4.00’’)
5 44 mm (1.732’’) 6 100 mm (4.00’’)
- 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 the instructions in the operator's
manual provided with the PTO shaft.

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4.2.7 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 check the hydraulic hoses. 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.
4.2.8 Remote controlled components
Danger of crushing and shearing can exist when
components are operatedby hydraulic or pneumatic
controls. Keep away from these danger zones.

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4.2.9 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.
4.2.10 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.

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Gross weight and weight per axle
- Respect the tractor gross weight, its lift capacity
or the permissible maximum load on the
attachment and the maximum load per axle.
- The front axle load (1) must never, under any
circumstances, be less than 20% of the tractor's
unladen weight. If necessary, add ballast weights
to the front or to the rear to preserve the steering
and braking efficiency.
- Do not exceed the gross machine weight ratingor
the maximum machine axle load allowed.
For machines with hoppers or tanks:
- If the total weight exceeds the machine's
total gross weight, empty the hopper to
travel on public roads.
- In any case, we recommend to travel on
public roads with empty hoppers and
tanks.
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.
- Always obey current regulations for driving
on roads.
kg
lb
kg
lb
1

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4.2.11 Maximum speed
- Always keep to the legal speed limit for driving a
tractor-machine assembly on public roads.
4.2.12 Tyres
- Regularly check the tyre pressure. Respect
manufacturers' recommendations on pressure.
Assembly, disassembly and repair of wheels and
tyres must only be carried out by competent
persons who are equipped with standardized
tools. Before any work is performed on the
wheels, ensure that the machine rests on the
ground and is perfectly stable so that it cannot
move accidentally (put chocks in place).
4.2.13 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.
4.2.14 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.

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4.2.15 Precautions for machine use
- After each use, check the cutting tools (discs,
knives) and their attachment hardware in
accordance with the instructions given in the
present manual. Immediately replace any worn,
damaged or missing cutting tool or element. To
do this, use the tool outfit supplied with the
machine. For your safety, only use genuine
parts !
- Regularly check the condition of the protection
covers. Immediatly replace any worn, damaged
or missing cover. Before engaging the PTO, rest
the cutterbar on the ground. 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, cuttings tools
can continue rotating for some time. Stay away
from the machine until all moving parts have
come to a complete standstill.
- If the machine hits an obstacle, 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.

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4.2.16 Projection of stones and foreign
objects
- For driver safety, always use a tractor equipped
with a cab. Keep the ground to mow free of
foreign bodies. Avoid mowing on stony or rocky
grounds. If this is not possible, take extra safety
precautions, such as:
- Fit polycarbonate screens inside the tractor cab's
side and rear windows, or install narrow mesh
guards on their exterior.
- Increase the cutting height to avoid contact with
stones or rocks.
- Never start a mower conditioner when other
people are close.
- 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.
- The protection covers help reducing risks of
projections. Therefore, make sure that all mower
protection devices are in place and good
condition prior to using the machine.
- Regularly check the condition of the protection
covers. Immediatly replace any worn, damaged
or missing cover.