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FC 855

Instruction Manual

“Original instructions”

Edition 2 I April 2010

Precision Chop Forage Harvester

Summary of Contents for FC 855

Page 1: ...FC 855 Instruction Manual Original instructions Edition 2 I April 2010 Precision Chop Forage Harvester ...

Page 2: ...p IT Tipo NL Type FR Modèle FC 855 ES modelo PT Marca DA Typ PL Model FI Merkki EN ES DE PT IT DA NL PL FR FI to which this declaration relates corresponds to the relevant basic safety and health requirements of the Directive 2006 42 EC al cual se refiere la presente declaración corresponde a las exigencias básicas de la normativa de la y referentes a la seguridad y a la sanidad a que se refere es...

Page 3: ...is instruction manual very carefully before using the machine Pay special attention to the safety instructions This instruction manual is made so that the information is mentioned in the order you will need it i e from the necessary operation conditions to use and maintenance Besides this there are illustrations with text Right and Left are defined from a position behind the machine facing the dir...

Page 4: ...acement of wearing parts 16 Safety decals 19 TECHNICAL DATA 21 2 CONNECTION TO TRACTOR 22 THE HYDRAULIC SYSTEM 22 ELECTRONICS 22 MOUNTING OF LIFT SUSPENSION 24 CONNECTION AND DISCONNECTION OF PRECISION CHOPPER 27 3 MOUNTING OF EQUIPMENT 29 HITCH FOR TRAILER 29 PICK UP 30 CHUTE AND DEFLECTOR 31 4 ADJUSTMENTS 33 PICK UP 33 ROTOR AND ROLLER SECTION 35 CUTTING LENGTHS 37 REPLACEMENT AND ADJUSTMENT OF ...

Page 5: ...ting 45 Blockage in the machine 46 6 MAINTENANCE 48 IN GENERAL 48 GUARDS 49 REPLACEMENT OF BLADES 49 TYRE PRESSURE 49 FRICTION CLUTCH 50 MISCELLANEOUS 52 Rollers 52 Electric motors 52 Chain tightener for pick up auger 52 7 GREASING 55 8 CABLING 56 9 STORAGE WINTER STORAGE 57 10 SPARE PARTS ORDER 58 11 DISPOSAL 59 PIGB 138X 02 FC 855 0410 5 ...

Page 6: ...echnically correct use is a matter of course The precision chop forage harvester FC 855 should only be used maintained and repaired by persons who through relevant instructions and after reading the instruction manual are familiar with the machine and in particular are informed of possible dangers In the following there are a number of general and special safety instructions which must be observed...

Page 7: ...akes it possible to remove a blockage without having to leave the tractor seat The intention is that the inexperienced user increases the forward speed gradually in the beginning until the pick up is blocked releases the blockage again by reversing and chooses a tractor gear at a suitable lower level to reduce the risk of blockage However it is not the intention that the clutch function of the fee...

Page 8: ...educed when cutting whole crops to ensure greater damage of the grains The shorter cutting length will of course require more power for which reason there will be a lower output when cutting whole crop than when cutting grass though it is difficult to compare The power requirements are also increased when the blades are worn and the shearbar adjustment thereby changes It is necessary to sharpen th...

Page 9: ... connect the machine to the tractor Even though you have been driving a similar machine before you should read the manuals this is a matter of your own safety You should never leave the machine to others before you have made sure that they have the necessary knowledge DEFINITIONS The safety decals and the instruction manual of the machine contain a line of safety notes The safety notes mention cer...

Page 10: ...r suitable shoes to avoid falling 8 Do not change the guards or work with the machine when a guard is missing or defective 9 Always drive with the statutory lights and safety marking during transport on public road and at night 10 Limit the transport speed to maximum 30 km h if the machine has not been marked with another maximum speed limit 11 Do not stand near the machine while it is working 12 ...

Page 11: ...the locks on the machine Fig 1 1 Fig 1 2 CHOICE OF TRACTOR Always follow the recommendations specified in the instruction manual of the tractor If this is not possible technical assistance must be sought Choose a tractor which has minimum 55 KW 75 HP at the power take off but cannot deliver more than 92kW 125 HP The machine is as standard constructed for 540 RPM or 1000 RPM and is delivered from t...

Page 12: ...ng period may damage the machine and at worst result in ejection of parts through the delivery chute Make sure that the PTO drive shaft has been mounted correctly i e that the lock pin is in mesh and that the support chain has been fastened at both ends Fig 1 3 Fig 1 4 The PTO drive shaft must be correctly protected If the guard is damaged it must be replaced immediately Check that all hydraulic c...

Page 13: ...revent them from blocking or damaging the machine and to avoid metal parts being thrown out from the delivery chute Check periodically if blades and blade bolts are worn according to the rules in the instruction manual The first time you use the machine the blades and blade bolts may bed in For this reason you must check and tighten the blade bolts after the first working hour When lifting the del...

Page 14: ...e parking brake and wait until the revolving parts have stopped before removing the material or the foreign matter Unfortunately this cannot be said too often Never remove material blocked in the machine while the machine is running and never feed material into the pick up with your hands or feet as there is a serious danger of getting caught and pulled into the harvester which would cause dismemb...

Page 15: ...ce to give access to the blade cylinder 3 Adjust the stone and guard the grinding device again 4 Remove the guard above the blade cylinder transmission and change the direction of rotation of the rotor 5 Fasten the guard again and check that there are no persons near the machine 6 Start the tractor again and keep the rpm close to idling 7 Perform the grinding carefully Always use safety glasses wh...

Page 16: ...hstand extreme stress Damaged blades blade bolts or shearbars must be replaced by original JF STOLL spare parts to ensure safe operation PR11 0232 Min 12 mm Blades and blade bolts must be checked every day during the season The special blade bolts must be tightened with a torque wrench to 40 kgm When the blades have been worn max 8 mm or approx 12 mm above the straight piece they must be replaced ...

Page 17: ...1 INTRODUCTION PIGB 138X 02 FC 855 0410 17 ...

Page 18: ...1 INTRODUCTION 4 3 1 2 6 5 8 9 7 12 10 11 4 7 5 8 8 8 9 3 10 2 1 12 6 11 PIGB 138X 02 FC 855 0410 18 ...

Page 19: ...arts After the PTO drive shaft has stopped the blades will have a momentum where they keep rotating for up to 2 minutes Wait until the blades have come to a complete stop before removing guards for inspection or maintenance 8 Risk of getting pulled into the machine Do not stand near the attachments or the feed rollers while the machine is running Make sure that the tractor engine has stopped first...

Page 20: ...1 INTRODUCTION PIGB 138X 02 FC 855 0410 20 ...

Page 21: ...lectric Electrical functions Chute swivelling deflector and reverse Hydraulic functions Pick up lifting Turning angle for chute 180 degrees Pick up pre lubricated Standard Weight with pick up 1600 kg Length max 4 1 m Max width with pick up 2 5 m Max height 3 6 m Tyre dimension standard 23 10 5 x 12 Freewheeling clutch in PTO shaft Standard Friction clutch in PTO shaft Standard 1050 Nm Steel wheels...

Page 22: ... hitch which is optional equipment ELECTRONICS PR12 0206 A PR12 0207 B C Fig 2 1 Fig 2 2 Fig 2 1 The reverse function the swivel chute and the deflector on the chute are controlled Fig 2 2 by electric motors A B and C The motors are operated from a control panel in the tractor cabin B C A Fig 2 3 Fig 2 3 Mount the holder A for the control panel in a suitable place within the reach of the tractor d...

Page 23: ...vise you not to connect to for instance the wiring of the lights as the wire thickness for these systems is usually not sufficient to transfer the necessary power PR11 0205 Fig 2 4 Fig 2 4 Mount the 7 pole socket mounted on the cable from the control panel at the rear of the tractor just outside the cabin with the supplied wing nuts The 7 pole plug from the machine can now be connected to the cont...

Page 24: ... the PTO shaft is mounted Fig 2 6 Fig 2 6 The PTO of the tractor and the PIC Power Intake Connection of the machine must be parallel i e the angle between them must be as close to 0º as possible The suspension is adjusted so that the PTO shaft in working position is maximum 10 higher or lower than horizontal This corresponds to the PIC input shaft of the gearbox being maximum 100 mm higher or lowe...

Page 25: ...pins 6 are placed so that the precision chopper gets as close to the tractor as possible The rear hole at long link arms The front hole at short link arms E The PTO shaft 7 is adjusted in length and mounted PR11 5017 Fig 2 8 Fig 2 8 The length of the PTO shaft is adjusted so that it in working position has minimum 200 mm overlap In no position is compressed more than the prescribed 30 mm in order ...

Page 26: ...age frame is mounted in the lift arms of the tractor The L frame hoop 3 is pushed onto the 3 point linkage frame 5 You should read and observe the instructions in the instruction manual for your tractor as regards connection of implements in the tractor hydraulics You should be especially aware of the fact that if the tractor hydraulics is with weight transfer that is activated by the top link fix...

Page 27: ...em is fastened in the tractor and the machine is ready for use Disconnection takes place by first removing the chute control system and the PTO shaft from the tractor After that the 3 point linkage frame is lowered until the machine rests on the ground Now the locking pawl in the front attachment point is released by pulling the cord When the 3 point linkage frame is raised again while pulling the...

Page 28: ...hing the ground The big movement at the front is obtained by mounting the top link high on the tractor and low on the suspension PR11 0352 Fig 2 12 Fig 2 12 If you are driving with more trailers that must be connected and disconnected for every load it is an advantage if the suspension gives a big movement up and down at the rear Thereby it becomes easier to pick up the trailer from the ground wit...

Page 29: ...itch eye Fig 3 2 Fig 3 2 For connection with hitch the 3 point linkage frame is lowered so that the hitch hook can get in under the hitch eye of the trailer The tractor is backed towards the trailer and the 3 point linkage frame is raised When the hook is in mesh with the hitch eye the trailer is connected For disconnection the cord for the hitch lock is pulled and the 3 point linkage frame is low...

Page 30: ...n the suspension A or a firm hitch which is mounted on the 3 point suspension frame B PICK UP PR12 0212 A B Fig 3 4 Fig 3 4 Wheel the pick up on the rollers to the machine so that the catch A is engaged Mount the 2 pins to fix the pick up to the basic machine The relief device is attached to the pick up at B PIGB 138X 02 FC 855 0410 30 ...

Page 31: ...ounted and adjusted the assembled fittings are mounted as shown on the figure Place the bracket A above the adjusting bar and assemble it then mount and fasten the bracket B Grease the swivel ring and check that the delivery chute can turn freely IMPORTANT Grease the swivel ring while turning the delivery chute manually to distribute the grease PIGB 138X 02 FC 855 0410 31 ...

Page 32: ...o the socket at the tractor cabin according to the section ELECTRONICS in chapter 2 CONNECTION TO TRACTOR Check that right left turn of the chute and up down movement of the deflector correspond with the marking for the joystick on the control panel in the tractor cabin If the movements and the marking do not correspond the wires in the assembly box on the motor s in question must be exchanged to ...

Page 33: ...ds a distance between the pick up tines and the ground of 15 to 20 mm Fig 4 2 Fig 4 2 With the spindle A the relief springs are tightened so that the pick up will have a maximum pressure towards the ground of 30 kg Check this by standing in front of the pick up and pull the hoop upwards and estimate the ground pressure When the machine stands on even ground the limiting rod B must be in the middle...

Page 34: ...ou stop and force the crop out of the machine by means of the reverse function See also chapter 5 DRIVING IN THE FIELD A continuous and even flow through pick up and auger is the best way to avoid blockages inside the machine otherwise more operational stoppages may occur The operator should always ensure spare friction discs for the slip clutch on the auger are in the tool box If this clutch has ...

Page 35: ...a scraper for the smooth roller E The scraper is mounted together with the reversible shearbar just mentioned When mounting the scraper place it as close as possible not damaging the smooth roller E the distance X must be between 0 25 and 0 5 mm then tighten the bolts F with a torque wrench to 10 12 kgm 100 120 Nm PR12 0458 A B Fig 4 5 Fig 4 5 The scraper is dismounted by removing the screws F on ...

Page 36: ...the crop substance small particles can accumulate in the shaded area see arrow on fig 4 7 this may result in an overloading of the transmission driving the rollers Check the area after every 8 hours of operation and remove possible crop remains Check and if necessary adjust the distance between scraper and smooth roller see fig 4 4 The checking frequency can be reduced when the operator knows the ...

Page 37: ...d row of blades 1 Number of blades on the rotor All cutting lengths can be doubled by removing every second row of blades PR11 0235 A1 B C Fig 4 9 Fig 4 9 2 Feed intake speed which is changed by using the following sprocket wheels Sprocket wheel No Number of teeth Z 2064 448X 14 2064 449A 18 2065 460X 21 2064 450A 25 2064 451A 30 2062 442X 36 PIGB 138X 02 FC 855 0410 37 ...

Page 38: ...ecessary to replace the opposite blade as a used blade has a different weight compared to a new blade Even if there is no visible damage to the blade bolts they should always be replaced together with the blades as they might have been overloaded CAUTION Check the distance between the blade and the shearbar 0 5 mm with the supplied gauge before and after the bolts are tightened WARNING Only use or...

Page 39: ... rotor has come to a complete standstill The rotor may only rotate when the grinding device is in grinding position Check before grinding that the grindstone is undamaged that the device is easily sliding back and forth that the device is parallel with the rotor The grinding device is correctly adjusted from the factory and therefore there is normally no need for adjustment but if it has been dism...

Page 40: ... 4 12 2 Lower the guard between the grinding device and the rotor so that there is free space between the device and the rotor PR12 0220 A Fig 4 13 Fig 4 13 3 Adjust the grindstone so that there is 2 3 mm clearance between the stone and the blades by turning the handle A PIGB 138X 02 FC 855 0410 40 ...

Page 41: ...ning the handle A until the stone touches the blade Move the stone in a sliding movement across the whole rotor and back again Feed some more and repeat the movement across the whole width of the rotor 8 Push the handle in after grinding Stop the tractor and when the rotor has come to a complete stop the guard between the device and the rotor must be lifted back into its right position The PTO dri...

Page 42: ...en working with the harvester it is necessary to make a rough grinding or adjustment of the blades when the cutting edge is 5 mm wide or more Grind the rear edge to an angle of approx 15o Rough grinding can be made by means of an angle grinder with the rotor and blades positioned in the machine CAUTION Be careful not to grind down the cutting edge front edge of the blades Block the rotor with a fi...

Page 43: ...s a constant pressure between the two parts B and C CAUTION Only use the reverse function for short periods to ensure correct functioning and long life of the rubber disc PR12 0238 B A Fig 4 20 Fig 4 20 The tightening of the V belt drive is also adjusted automatically It is determined by the electric motor A which always drives with the same constant power IMPORTANT If the tightening of the belt d...

Page 44: ... intake section under such conditions At the same time you will have optimal preconditions for problem free reverse out of the auger as the feed intake plate A usually tends to prevent the crop from being reversed freely out of the auger Under difficult conditions we recommend you to bring spare friction discs for the slip clutch on the auger as the pre adjusted torque on a slip clutch falls gradu...

Page 45: ... long as the tractor can keep the required number of revolution of approx 540 or 1000 rpm An inexperienced operator should always work with a capacity reserve in the machine to avoid problems with the flow through the machine IMPORTANT Always make sure that the tractor can keep the correct number of revolutions of 540 1000 rpm on the PTO This ensures a regular load of the machine and you avoid tor...

Page 46: ...uger and the feed intake stop immediately and you can obtain an overview of the situation Now place the reverse system in reverse position at a low number of rpm with the switch on the panel and reverse the material out of the machine We recommend to reverse slowly with the machine when the material is pushed out Thereby you avoid accumulation of material behind the pick up auger and in front of t...

Page 47: ...nding or for reverse in case of blockage in the auger or the feed intake section 3 Connect the power take off again at low number of rpm and move the reverse function to reverse position with the toggle switch on the control panel and reverse the material out of the machine PR12 0460 A B Fig 5 6 Fig 5 6 4 After reversing disconnect the tractor s power take off again stop the tractor and move the P...

Page 48: ...tightened after some hours of operation This also applies if repairs have been made Especially the bolts for the blades on the rotor must be retightened carefully Torque moment MA for bolts on the machine if nothing else stated in this instruction manual A Ø Class 8 8 MA Nm Class 10 9 MA Nm Class 12 9 MA Nm M 8 25 33 40 M 10 48 65 80 M 12 80 120 135 M 12x1 25 90 125 146 M 14 135 180 215 M 14x1 5 1...

Page 49: ...e locks on the machine REPLACEMENT OF BLADES See description for replacement of blades in the rotor and the subsequent adjustment in the section REPLACEMENT AND ADJUSTMENT OF BLADES in chapter 4 ADJUSTMENTS TYRE PRESSURE The below table indicates the recommended tyre pressure FC 855 Tyre dimension Tyre pressure Machine 23x10 5 12 4 Max 1 4 bar Support wheels 500 8 Max 2 4 bar Rubber wheels for pic...

Page 50: ...is in function slips The auger is also fitted with a friction clutch as described in the section PICK UP in chapter 4 ADJUSTMENTS The friction clutches must be maintained at regular intervals At the same time the clutches must be checked if they have not been in operation for some time This especially applies after winter storage before the machine is used for the first time in the season Maintena...

Page 51: ...auger PR12 0708b A C B D Fig 6 5 Fig 6 5 1 Disassemble the clutch and clean all parts of possible rust 2 Check the clutch discs A for wear and replace if required 3 Assemble and mount the clutch again Tighten the bolts B with normal torque as the flange C ensures the correct compression of the springs D and thus the correct torque setting WARNING If the clutch is overloaded by slipping for some ti...

Page 52: ... to avoid formation of rust When dismounting the control panel in the cabin it should be stored in a dry and warm place The plugs on the cables of the machine must be placed under a guard or wrapped up to protect against wind and weather They can be treated with spray CHAIN TIGHTENER FOR PICK UP AUGER PR12 1181 B A A Fig 6 7 Fig 6 7 Two bolts A are loosened after which the eccentric B can be turne...

Page 53: ...6 MAINTENANCE PIGB 138X 02 FC 855 0410 53 ...

Page 54: ...7 GREASING 13 3 2 2 3 4 8 12 15 11 11 1 11 11 5 1 1 5 10 6 PR11 0355 17 16 18 18 10 16 18 10 10 7 7 7 7 9 14 14 19 Greasing once a day Greasing once a week 18 PIGB 138X 02 FC 855 0410 54 ...

Page 55: ... rollers 8 5 Bearings for tube in the pick up 2 17 Swivel chute 4 8 Grinding device 1 9 Support rollers 3 14 Link bearings in rocker arms 2 10 Bearing housing 4 11 Couplings 3 19 Alternative pin for transmission shaft at rotor grinding blocking 1 12 Steering device for grindstone rust preventing oil 2 After every 500 hours of operation or once a year the following must be greased 16 Support arm fo...

Page 56: ...8 CABLING 8 CABLING PIGB 138X 02 FC 855 0410 56 ...

Page 57: ...ut of the bearings IMPORTANT Grease all grease points after cleaning the machine The following points are instructions how to prepare for winter storage Check the machine for wear and other defects note down the necessary parts you will need before the next season and order the spare parts Dismount the PTO drive shafts lubricate the profile tubes and keep them in a dry place Spray the machine with...

Page 58: ...ial number This information is printed on the machine plate We request you to write this information on the first page in the spare parts book supplied with the machine as soon as possible so that you have the information at hand when ordering spare parts PR11 1317 PR80 3393 PIGB 138X 02 FC 855 0410 58 ...

Page 59: ...s cylinders and hoses must be emptied of oil These oils must be handed over to a destruction company Disassemble the machine and separate the individual parts e g PTO drive shafts tyres hydraulic components etc Hand over the usable parts to an authorised recycling centre The large scrapping parts are handed over to an authorised breaker s yard PIGB 138X 02 FC 855 0410 59 ...

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Page 63: ...as expenses for oil grease and minor adjustments 2 Transport of machine to and from workshop 3 The dealer s travelling expenses or freight charges to and from the user Warranty is not granted on wearing parts unless it can clearly be proved that JF has committed a fault The following is regarded as wearing parts Protective canvases blades blade suspensions shearbars guide shoes stone protections d...

Page 64: ...rience from right around the world and more importantly unique regional requirements We also receive important inspiration in our development work through a close and continuous dialogue with customers dealers and agricultural researchers No matter which type of JF STOLL machine you chose you can be sure to obtain the best result to obtain a top result in the shape of high performance and operatio...

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