KUHN FC 4000 G Owner'S/Operator'S Manual Download

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FASTENER TORQUE CHART

All the hardware used on the FC4000 is metric sized, and the minimal class quality hardware
used is 8.8. If any hardware is missing, replace it only with genuine Kuhn spare parts.
Use the following values if nothing has been specified :

Regular metric thread
DIN 13 - ISO/R 262

Class 8.8

Class 10.9

Class 12.9

N.m

lb-ft

N.m

lb-ft

N.m

lb-ft

M10

M12

125

145

105

M14

135

200

145

235

170

M16

210

150

310

225

365

265

M18

300

220

430

310

500

360

M20

425

310

610

440

710

510

M22

580

420

830

600

970

700

M24

730

530

1050

760

1220

890

MAINTENANCE

Summary of Contents for FC 4000 G

Page 1: ...OWNER S OPERATOR S MANUAL FC 4000 R FC 4000 RG FC 4000 G N 95109 C GB 10 2004...

Page 2: ...MANUAL SHOULD REMAIN WITH THE MACHINE WHEN SOLD Your KUHN dealer will instruct you on the general operation and maintenance of your machine Your KUHN dealer is interested that you get the best perfor...

Page 3: ..._____________________________________________ 30 FIELD OPERATIONS __________________________________________________________________ 33 LUBRICATION____________________________________________________...

Page 4: ...d will result in death or serious injury This signal word is to be limited to the most extreme situations typically for machine components which for functional purposes cannot be guarded WARNING Indic...

Page 5: ...esignated use of the machine also means Following operation maintenance and repair recommendations given by the manufacturer Using only genuine spare parts equipment and accessories as designated by t...

Page 6: ...y covers shields and other compo nents are removed from the machine 5 DO NOT USE the mower to cut anything without the cutterbar in contact with the ground 6 DO NOT OPERATE the mower at unsafe speeds...

Page 7: ...d cab with a R O P S 7 Before starting up the machine and beginning work check the surrounding area beware of children Make sure there is sufficient visibility Keep all people and animals away from th...

Page 8: ...be cautious in every given situation 21 Be particularly cautious when turning corners paying attention to machine overhang length height and weight 22 Before operating the machine ensure that all safe...

Page 9: ...ft arms should be stabilized by the linkage to avoid lift arm side to side shifting 8 Always ensure that the machine and tractor combination is stable and safe when operating or transporting the machi...

Page 10: ...move accidentally put chocks in place 2 Assembly disassembly and repair of wheels and tires must only be carried out by competent trained persons using proper tools and equipment 3 Check tire pressure...

Page 11: ...e and remove ignition key 2 Check tightness of all nuts bolts and all other fasteners regularly Retighten if necessary 3 If the machine is raised prop it up in a stable position before carrying out an...

Page 12: ...s protection cover Worn or damaged protection cov ers must be replaced immediately 8 Protection devices such as guards shields etc are intended to prevent stones rocks or other foreign objects from b...

Page 13: ...ve moving parts continue to rotate for some time Wait for all moving parts to come to a complete stop before leaving the cab and approaching the machine 16 If an obstruction is hit stop the tractor im...

Page 14: ...ARE DAMAGED MISSING OR ILLEGIBLE REPLACE THEM BEFORE OPERATING OR DE LIVERING THE MACHINE THE FOLLOWING SAFETY PICTORIALS HAVE BEEN PLACED ON THE MACHINE IN THE AREAS INDICATED THEY ARE INTENDED FOR T...

Page 15: ...13 SAFETY DECALS...

Page 16: ...m swath width depends on crop conditions 3 Maximum swath width 10 Minimum recommended tractor PTO 110 hp 81 kW Free wheel and friction slip clutch Standard CV primary PTO shaft yes Hourly work rate ap...

Page 17: ...tioning Hitch Straight hitch ASAE standard drawbar hitch cat II or III Gyrodine swivel hitch ASAE standard 3 point hitch cat II or III PTO 1000 rpm only with 1 3 8 x 21 spline shaft A 1 3 4 x 20 splin...

Page 18: ...the three point hitch all the way up or all the way down so they will not interfere with the hitch or PTO of the mower while turning Adjust the length of the tractor s draw bar to the 1000 rpm positi...

Page 19: ...nd hitch c Connect the hydraulic hoses Two hydraulic remotes are required The hose with a white band is for mower s lift cylinders Connect hose to the outlet for proper single acting operation The oth...

Page 20: ...m Connect the PTO shaft and hook up the retaining chains to prevent the PTO guard from rotating f Unhooking from the straight hitch WARNING Always park the machine on level ground Lock the tongue in t...

Page 21: ...amaged guards must be replaced immediately b Back the tractor up to the mower conditioner and attach lower links 7 to the pivoting yoke 6 with linchpins 3 For cat II tractors use 1 10 28 mm hitch pins...

Page 22: ...the tubes and the yokes Bevel and de burr transmission tubes Remove all steel chips and filings Grease the inside of the outer transmission tube Shorten the guard tubes by the same length as the trans...

Page 23: ...ongue in the transport position lower the header Fully raise the tractor lower links Warning To avoid serious injury or death stop tractor engine disengage the PTO shift to park position or shift to n...

Page 24: ...ly and are in good condition see maintenance chap ter Perform all of the daily lubrication required and items whose periodic maintenance is due see lubrication chapter Check all hydraulic connections...

Page 25: ...ht PREPARATION FOR TRANSPORT The machine must be put into the transport position when traveling on public roads Proceed as follows Raise the header all the way up To avoid serious injury or death stop...

Page 26: ...ls it is recommended to only work at 4 10 cm with the mower conditioner unit suspension system adjusted to the minimum ground pressure This results in better cutterbar ground clearance improved ground...

Page 27: ...cular feature has been obtained by connecting the header with two main rods pushing upward Set the suspension for the minimum weight possible in order to prolong the life of the cutterbar components b...

Page 28: ...ght 4 with the high skid shoes and adjust the header at the minimum ground pressure The header will float over bumps the high skid shoes will give clearance between the ground and the cutterbar for lo...

Page 29: ...unit These baffles will re direct down half of the crop flow coming out of each set of rolls The other half will be directed to the windrow forming shields and will fill the middle of the swath This a...

Page 30: ...The position of the baffle will depend on the crop density Fully open the two windrow forming shields 5 and lock them using handles 4 To windrow Adjust the two swathing baffles 1 all the way up on bo...

Page 31: ...s 2 towards the ground Fully open the two windrow forming shields 3 and lock them using handles 4 To windrow Completely lift the two swath flaps 1 on each side by folding levers 2 upwards The FC 4000...

Page 32: ...checked See diagram below E Recommended gap 1 8 3 mm If gap is out of adjustment proceed as follows Note Do not attempt to adjust roll gap un less there is tension on the rolls Loosen the locknuts 1...

Page 33: ...increase conditioning Loosen the locknut 1 Tighten nut 3 two full turns Tighten locknut 1 Operate mower conditioner and evaluate conditioning If more conditioning is required repeat proceedure To dec...

Page 34: ...the hood 2 increases thus reducing the conditioning intensity Ontheotherhandthreearticulationpoints A and B are available in order to adapt the position of the conditioning hood 2 to the variousworkin...

Page 35: ...cut when the tractor is driving right above the previous cut windrow and when the tongue is swung all the way over 180 TURN The center pivot design allows the operator to mow a field back and forth b...

Page 36: ...tor at first away from the uncut crop 2 Swing the tongue half way toward the center of the machine while turning the tractor It might seem like the tractor and the tongue are turning around the center...

Page 37: ...nce a year Roller drive chains 2 200 hours or once a year GEARBOXES For proper machine operation use API 80W 90 GL5 EP type gear oil or equivalent EP Extreme pressure Never use a straight 90 weight oi...

Page 38: ...1 2 3 4 5 6 7 8 9 10 Every 20 hours pull the front half of the PTO out and grease the telescopic tube 11 Note The central grease fitting 2 and 8 should be lubricated when the double joints are straigh...

Page 39: ...rease fittings 1 2 3 4 To gain access to the telescopic tube grease zerk raise the header and swing the tongue in transport position This is the position required to access the grease zerk 5 Rotate th...

Page 40: ...ings before applying grease Lubricate the grease fitting 1 Center pivot Bushings Every 10 hours of use or once a day Clean fittings before applying grease Lubricate grease fittings 1 2 Swing Cylinder...

Page 41: ...once a year Clean fitting before applying grease Lubricate grease fittings 1 Roller drive chains FC 4000 R RG Every 200 hours of use or once a year Remove the chain cover Clean the chain and the chai...

Page 42: ...el Cutterbar a Checking the oil level Tilt the header to 0 Lower the cutterbar to a level surface Make sure to level the cutterbar from left to right Correct oil level is 1 8 3mm at both filler plugs...

Page 43: ...wer the cutterbar onto the blocks Remove end plate 1 from the lower end of the cutterbar and collect the oil in a container of at least 3 qt capacity Allow oil to drain completely Reinstall the drain...

Page 44: ...plug 3 and remove the plug Asmall amount of oil may drain out Add 80W 90 GL5 oil through the fill plug hole 1 until oil begins coming out the drain hole 3 Reinstall the plugs with a new copper seal i...

Page 45: ...Checking the level of the oil should be done with the whole of the dip stick screwed in b Oil change After the 10 first hours then every 200 hours or once a year Remove the dip stick 1 Place a bucket...

Page 46: ...l level Refill if necessary using 80W 90 GL5 oil Reinstall the fill plug b Draining After the first 10 hours then every 200 hours or once a year Remove plug 1 to release any excess pressure Put a cont...

Page 47: ...l Reinstall the fill plug using a new copper sealing ring b Draining After the first 10 hours then every 200 hours or once a year Remove plug 1 to relieve pressure in the gearbox Put a container under...

Page 48: ...ions and standards as defined by the manufacturer Use only genuine KUHN parts 9 Before any electric welding is carried out on tractor or attached machine disconnect alter nator and battery terminals 1...

Page 49: ...e fol lowing cases a Damaged blades Check for bent blades The blades must be straight and should turn freely around the bolt IF A BLADE IS BENT REPLACE IT DO NOT ATTEMPT TO STRAIGHTEN IT AS THIS WILL...

Page 50: ...d reaches the con tact area of the blade When the diameter D of the bolt shoulder is less than 5 8 15 mm 3 Nut inspection a Tightening torque 90ft lbs 12 daNm Check at the beginning of the season Insp...

Page 51: ...t and nuts inspection in this chapter Reverse the blade or replace it Directional arrows are stamped in each blade 559 032 10 for counter clockwise rotating discs and 559 033 10 for clockwise rotating...

Page 52: ...weld a disc Each disc is balanced to rotate at 2700 rpm without vibrations Welding on a disc can unbalance the disc and can create strong vibrations and accelerate the wear of the mower Always replac...

Page 53: ...em by a pair worn in the opposite direction see diagram on page 47 IMPORTANT Half discs are balanced by pair they must not be mixed Half discs are only sold by the pair Install the new half discs and...

Page 54: ...clutch springs or all the protection to the drive com ponents will be lost b If the clutch slips excessively Stop the tractor engine shift to park or apply the tractor s parking brake and take the ke...

Page 55: ...the lower span of the chain tight align marks A B and slide both sprockets and chain onto the shafts Make sure the closed end of the master link clip is leading in direction of normal chain movement...

Page 56: ...ntral gearbox is oriented by a double acting cylinder This cylinder is connected in series with the swing cylinder of the tongue See hydraulic schematic next page If repairs have been made to the hydr...

Page 57: ...55 MAINTENANCE 2 Hydraulic schematic...

Page 58: ...56 MAINTENANCE ELECTRIC CONNECTORS...

Page 59: ...lowing values if nothing has been specified Regular metric thread DIN 13 ISO R 262 Class 8 8 Class 10 9 Class 12 9 N m lb ft N m lb ft N m lb ft M6 10 7 15 11 18 13 M8 25 18 36 26 43 31 M10 49 35 72 5...

Page 60: ...ting devices needed to safely remove it from the ma chine Check that the brass bush is correctly installed in the hitch tube Pack with grease Install the new hitch tube by proceeding in reverse order...

Page 61: ...ect grade oil see the lubrication section Apply grease to all fittings as described in the lubrica tion section 5 Store the machine in a dry place 6 Park the machine in transport position Grease the r...

Page 62: ...orresponds with the disc s direction of rotation Damaged or broken blades Replace blades See blades repla cement in Maintenance chapter Poor cutting quality Insufficient PTO speed Bring PTO speed up t...

Page 63: ...ader back disc guards lighten the header put high skid shoes on Stubble too high Header incorrectly adjusted Lower cutting height by tilting the in down crop header forward Incorrect skid for conditio...

Page 64: ...roce insufficient FC 4000R RG dure inAdjustment Section under Conditioning Intensity Conditioning fingers worn Replace the conditioning fingers Excessive noise or missing FC 4000 G or vibration Damage...

Page 65: ...er uneven speed ground Uneven adjustment of the Check the weight of the header suspension springs at both sides Windrow forming shields Open the windrow forming shields closed too far Insufficient PTO...

Page 66: ...be paid in accordance with the warranty agreement of the manufacturer concerned in as much as the latter justifies such a claim 3 This Limited Warranty will be withdrawn if any equipment has been use...

Page 67: ...uct registration form has been correctly completed by dealer and purchaser with their names and addresses dated signed and returned to the appropriate address as given on the warranty product registra...

Page 68: ...such changes on units previously manufactured Moreover because of the constant progress in technology no guarantee is given to the descrip tions of equipment published in any document by the company D...

Page 69: ...67 NOTES...

Page 70: ...68...

Page 71: ...althandSafetyregulationsaswellastheHighwayCode For your own safety use only genuine KUHN spare parts The manufacturer disclaims all responsibilities due to incorrect use or non compliance with the rec...

Page 72: ...ION OF THE MACHINE USE ONLY GENUINE KUHN PARTS KUHN FARM MACHINERY INC 5390 East Seneca Street VERNON NY 13476 Phone 315 829 2620 Fax 315 829 2270 KUHN S A 4 impasse des Fabriques 67706 SAVERNE CEDEX...

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