Forage Harvester User Guide
Forage Harvester User Guide
Operating Manual
Issue B0509
English
No. 93 940
Champion C 1200
MOUNTED UNIVERSAL
FORAGE HARVESTER
2. The sharpening device may only be operated with the housing of the flywheel cutting disc closed. When
operating the mechanism, stand at the side of the machine. Use protecting spectacles.
3. Never attempt to feed the crop into the machine with your hands or feet.
4. Whenever working on the forage harvester, switch off the PTO and stop the tractor engine.
5. Before traveling on public roads always fold the guard frame over the stalk lifter.
6. Never open the housing of the flywheel cutting disc while the machine is running. DANGER! The cutting disc
will continue to rotate even if the machine is switched off.
9. Keep the PTO shaft guards in good condition and prevent the guard tubes from rotating by attaching the
provided safety chains.
10. Never cut rings from the guard cones of the PTO shaft.
11. Before carrying out any work under the machine, same has to proposed safely.
12. When traveling on public roads the discharge chute has to be positioned in such a way that is does not project
beyond the tractor or the implement, neither to the side nor to the rear.
13. Always comply with the lightening regulations in force of your country.
14. Do not allow anyone to stay in the slewing range of the discharge chute while cutting disc is rotating.
16. Relieve all pressures before disconnecting hydraulic lines. Report immediately to a doctor in case of injury by
hydraulic oil forced out under high pressure.
18. Before tracing a foreign object, switch off all drive mechanisms, stop the engine and wait for all moving parts
to stop.
19. The machine height must not exceed 4.3m to avoid touching power lines.
20. The hitch is not designed for supported any additional load.
21. All controls of the machine must be positioned on the tractor mudguard within the operator’s reach.
22. It may be necessary to install front ballast weights to ensure adequate steering capabilities of the tractor.
When installing ballast weights, do not exceed the permissible axle load.
23. Do not allow anyone to stay in the slewing range of the machine. Check that the machine id in a horizontal
position when swinging round. Failure to do so may cause the machine to swing round due to its weights
when the locking mechanism is released. Special care should be taken when operating on a slope.
24. The hydraulic system is under high pressure. All damages or deteriorated hoses have to be replaced
immediately. In any case the hoses and hydraulic lines have to be replaces every six years.
Hydraulik Druck
max. Hydraulic pressure of
Pression Hydraulique de
max.
rpm 2 1 0 bar
1 Safety instructions C 1200
Danger by turning cutting rotor. Keep Keep hands away from rotating crop
distance. dividers.
Put safety shields in place when grinding Wait until all machine components have
knives. Wear safety glasses. completely stopped before touching them.
1 Safety instructions C 1200
Stay clear of rotating drive line to avoid Avoid fluid escape under pressure.
personal injury. Read the users manual. Change hoses immediately.
Dear customer You have made a good choice. We are pleased to congratulate you on you
selection of a KEMPER machine. As your partner we offer quality and perfor-
mance, together with reliable service.
In order to be able to evaluate the conditions of use of our agricultural machi-
nes, and to take these requirements into consideration in the development of
new units, we ask you to provide some information.
This also allows us to inform you selectively of new developments.
Product Liability Product liability instructs manufacturers and dealers to hand over the
and Customer instruction manual with each machine and to give the customer practical
Information instruction on operation, safety and maintenance.
A multiple form (A,B,C) similar to the one illustrated below is supplied with
each Operator's Manual. Confirmation is required that the customer has taken
possession of the machine and the Operator's Manual.
For this purpose, send the signed document A to Kemper. Document B is
retained by the dealer who supplied the machine. Document C is retained by
the customer. At the same time you will be assured that warranty is given.
EC This product has been submitted to the CE test and has obtained the CE
Certificate of approval mark in conformity with EC Directive 2006/42/EG.
Conformity (Communauté europeenne / European Community). An EC Certificate of
Conformity is supplied with this manual. This certificate must be handed over
to the final owner of the machine together with the Operator's Manual.
Handing over the Attention! Even if the machine is sold at a later date by the customer, the
Operator's Operator's Manual must be handed over to the new owner.
Manual
This symbol will be found wherever safety advice is given in the manual.
Anyone operating this machine must be given all necessary safety instructions.
6 Introduction – Scope of application C 1200
1. Introduction
In addition to a comprehensive technical description, this manual contains
general and specific explanations concerning function and correct operation of
the CHAMPION and tips how to eliminate malfunctions.
Our policy is one of continuous development and improvement in line with the
latest scientific and industrial knowledge and the company therefore reserves
the right to alter specifications without prior notice.
Note the identification numbers of the machine on the last page of this manual.
This information will enable your dealer to send you quickly the correct spare
parts.
Mounting facility
The special drive system allows three mounting options with the same basic machine:
FRONT MOUNTING – REAR MOUNTING – SIDE MOUNTING
The machine can be hitched to any tractor with cat. II 3-pt hydraulics.
Power transmission
Main PTO drive shaft with friction clutch and freewheel mechanism.
Tractors PTO speed: 1000 rpm.
Divided drive system composed of two pivoted elements: one element has two angle gears for
FRONT and REAR mounting, the other is composed of a maintenancefree powerband belt drive.
Cutting unit
New row-independent cutting system composed of a fast rotating cutting rotor. The crop is cut over the
entire working width (1.25 m) by enclosed rotary cutting blades composed of replaceable segments.
Chopping unit
Centrally adjustable flywheel (1180 rpm) fitted with 12 chopping blades with tungsten carbide coating
and special profile for extremely efficient chopping; reversible shear blade with carbide tipped edges;
built-in blade sharpener; flywheel housing fitted with replaceable wear and tear plates; rasp concave
for more efficient re-chopping, useable instead of the smooth concave.
Feeding unit
It is composed of two feed rollers with toothed bars, one springloaded precompression roller and one
smooth roller for efficient crop compression before the flywheel. The feed and precompression rollers
are driven by an oil-bath gearbox. The unit is fitted with an overload protection.
Discharge chute
Foldable discharge chute with hydraulic slewing (140 W);
electrically adjustable discharge double flap;
one double acting control valve required on the tractor.
Chop lengths
Adjustable by changing the V-belt pulleys and by changing the number of blades.
Cutting lengths
V-belt pulley W Cutting knives
12 6
1 = 153 mm
4 8
65975
1= 218 mm
8.5 17
65977
9 Technical Data C 1200
Technical Data
Length m: 2.80
Width m: 1.76
Height in working position m: 3.95
Weight kg: 1100
Pto speed rpm: 1000
Power requirement kW/HP: min.: 50/70; max.: 110/150
Row interval cm: row-independent
Working width m: 1.25
Chopped lengths mm: 5 – 7.5 – 10 – 15 – 20 – 30
Mounting facility
The CHAMPION C 1200 can be operated by conventional tractors and by system
tractors as well. Hitch options are the combined REAR and SIDE MOUNTING and
FRONT MOUNTING. The new drive system allows any of these three options to be used
by swinging the divided transmission system into the desired position.
PTO
The main PTO shaft W 2400 is equipped wit ha slip clutch FK 96/4 (M = 1350 Nm). The
REAR and SIDE mounting versions have a clockwise free run and th e FRONT version
is equipped with an anti clockwise free running clutch.
Higher yields
The new method gives the following advantages:
• The individual plants are more conveniently positioned.
• Faster shading of the soil as a result of the smaller row spacing.
• Prevention of erosion.
• Better utilization of the nitrogen contained in the soil.
• Yields increase by approx. 12 to 17 %.
• Higher quality.
19 Technical instructions C 1200
19 Technical instructions C 1200
Steering capability Sufficient steering capability is only ensured if at least 20 % of the total
weights are acting onto the tractor front axle.
Hitch The hitch is not designed for supporting any additional load. Please
also observe the corresponding decal placed on the machine.
NOTE:
1. It is not permissible to hitch a two-wheeled trailer to a rear
mounted machine.
2. A four-wheel trailer may be attached if the following conditions
are fulfilled:
a) Maximum forward speed: 25 km/h
b) The trailer is fitted with an overrunning brake or with a
brake system which can be operated by the tractor driver
c) The permissible total weight of the trailer is not superior
to the permissible total weight of the tractor x 1.25, but at
most 5 tons.
Overload protection in the The friction clutch of the PTO drive shaft protects the drive system and
spur gear drive of the flywheel against overload. Any overload in the feed mechanism will
precompression rollers activate the pin type safety clutch fitted to the spur gear lubricated with
(Fig. 30) rolling bearing grease Gresalit LZ 2.
The torque of the clutch is preset. The housing is welded so that the
clutch cannot get loose and the torque settings cannot be modified.
Should it nevertheless be necessary to remove the clutch you should
note that the cup springs 180 are pre-tensioned and circlip 120 can only
be removed if this tension is released.
19 Technical instructions C 1200
19 Technical instructions C 1200
Overload clutch of the Another overload clutch is fitted to the feed drum. This clutch is only
feed drum operative with the power band set to the correct tension when spring 12
(Fig. 30 A) is so adjusted that the measurement 270 mm is given.
Main PTO drive shaft Specifications of the PTO drive shaft: size 2400, tubes S4LH/S5,
(Fig 31) friction clutch FK 96/4 with freewheel mechanism, independent of the
sense of rotation, clutch torque 1350 Nm, clevis 1 3/8, 6 splines, with
lock pin (tractor side). Clevis size for another tractor PTO’
s:
1 3/8 – 21 splines = PN 59025
1 3/4 – 6 splines = PN 63254
1 3/4 – 20 splines = PN 63255
For FRONT MOUNTING the PTO drive shaft is fitted with a ccw
rotating free running clutch:
Cpl. PTO drive shaft = 68951
½ PTO drive shaft with freewheel running mechanism: PN 69255
Friction clutch of the main PTO drive shaft – Fig 32
Overload protection The friction clutch in the main PTO drive shaft protects the whole
machine from overload. It is therefore INDISPENDABLE to check the
function of this clutch periodically.
Torque setting The clutch torque is set to 1350 Nm. To maintain this setting it is
essential to perform the maintenance jobs described in the following
two sections. Warranty will be voided if this advise is not observed.
Simple check To be carried out before the first use of the machine and after long
periods of storage:
• Tighten the nuts (2) to relieve the friction discs of load. Rotate
the clutch.
• Unscrew the nuts (2) up to the end of the threaded position.
Detailed check To be carried out at every start of season:
• Tighten the nuts (2) to relieve the friction discs of load.
• To maintain the torque setting (=1350 Nm) proceed as follows:
Mark position of adjusting ring 11 in relation to the clutch
housing. Then remove the adjusting ring.
• Remove cup springs, pressure discs, driving discs and hub.
Clean these components or replace them if necessary.
New slip pads After the installation of new slip pads, the clutch will only reach the full
torque after a running-in period.
• Engage the Champion slowly, avoid any unnecessary load of
the clutch
• The full capacity of the machine should only be utilized after a
running-in period.
22 Ejection chute C1200
Installation of ejection chute after delivery
Front-mounted Rear-mounted
Side-mounted
The Champion C1200 can be operated in three different positions to the tractor.
In order to mount the header to the front of the tractor, turn the input bevel gear
transmission (see instructions).
If the machine is to be operated to the side of the tractor, ensure that there is
sufficient space between the rear wheel of the tractor and the divider tip.
The headstock can be moved on the frame in order to adjust the forage harvester
to the tractor in an optimised position.
See also section "Attachment to tractor".
24 Attachment options C1200
Conversion for front mounting
Swivelling bevel gear transmission
Protective cap
Protective pate
Swivel protective plate
Securing key
Stop
Caution
It is forbidden to stand in the swivelling range of the machine. Before
swivelling the machine, ensure that the machine is attached in a
horizontal position. Otherwise, the machine might swivel due to its
own weight when the securing key is removed. Special care is
required when swivelling the attachment while the machine is
standing on a slope.
25 Working with the forage harvester C1200
Alignment of forage harvester
Cutting lengths
Cutting lengths
V-belt pulley Chopping blade
∅
12 6
1 =180 5 10
2 = 210
1 = 210 7,5 15
2 = 180
Fig. 40
Cutting lengths
V-belt pulley Chopping blade
∅
12 6
1 =153 4 8
2 = 218
1 = 218 8,5 17
2 = 153
Fig. 40A
The shortest standard chopping length is 5 mm. This length can be reduced to
4mm by using two V-belt pulleys.
V-belt pulley 1 153 = no.65975
V-belt pulley 2 218 = no.65977
Switch off all drives, shut down the engine and let all parts come
to a standstill.
Maize Select the travel speed to match the crop density. With short stemmed
maize forward speed should be increased to ensure a satisfactory flow of
chopped crop. Depending on the degree of dryness of the kernels the
smooth or friction concave plate should be used.
Whole crop silage Originally the Champion C 1200 is constructed for the harvest of thick
stemmed crops. With the help of the following tips as well as favorable
conditions of the crop like standing and dry crops, good results can be
achieved. Concerning the cutting length you should take compromises
because of its principle of construction of the cutting system.
• Dry crop
• Standing crop must have a minimum length of knee height
• Drive basically fast in order to get a enough food flow into the
chopper
• During extremely difficult conditions like wet laid crops with a lot of
weed on a sandy soil the operator should have some practice as
regards selection of the right forward speed, steering the machine
and use of the stem lifters.
Important!
Ensure that the grinding disk rotates
with the blades during grinding!
Adjust the speed! The faster the
blades rotate, the higher the abrasive
effect of the grinding disk!
Load shovels
Caution: The faster the blades rotate, the higher the abrasive effect of the
grinding disk!
To adjust the grinding effect, simply adjust the blade wheel speed.
If the speed is too high, the grinding disk surface becomes smooth and shiny. Its
coarseness can be restored by reducing the speed. If this is not effective, increase
the force with which the disk presses against the blades for a short time. It might
also be sufficient to produce a few small ridges produced with an angle grinder.
32.1 Inspection and adjustment of opposite cutting edge
Blade rotor & smooth roller C1200
Testing of counter-edge
Installation position
33 Replacing bottom plate C1200
Adjust the cracker plate to suit the type of the crop.
- Smooth plate for standard products
- Crushing plate for dry products
- By using the cracker plate, the maize corns are effectively ground to small
particles. This however requires a higher power input from the tractor.
Dismantling of cracker plate
The grinding effect of the cracker plate
can be adjusted by placing washers
between the cracker plate and the
housing. The smaller the gap between
the blade wheel and the cracker plate,
the smaller the corns are chopped.
The service life of the cracker plates can be prolonged by reversing their position
(items 1 + 2).
34 Maintenance & inspection C1200
Adjustment of belt tensioner The main drive belt is tensioned by a
pressure roller and spring. Adjust the
spring to a length of 83 mm.
Servicing intervals The indicated servicing intervals are calculated for normal operating
conditions. Before lubricating clean the grease nipples. Damaged grease
nipples have to be replaced. If a new grease nipple should not accept
grease, remove it and find the cause of blockage.
Caution!
Cleaning, lubricating and adjusting work may only be carried out with the
engine stopped. Wait for all machine components to be at a complete stop.
All lubricating and maintenance jobs have to be carried out before and after
every season.
M 18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410
M 20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580
M 22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800
M 24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000
M 27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500
M 30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000
M 33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750
M 36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500
The tightening torques are indicated in the table are approximately values and do NOT apply wherever
other tightening torques are quoted in this manual. Bolts and nuts have to be checked periodically for
tightness. The shear bolts are designed in such a way that they break if exposed to a determined load.
When replacing shear bolts use only bolts of the same property class.
When replacing bolts and nuts be sure that the replacement are the same or higher property class.
Bolts and nuts of higher property class have to be tightened to the same torque as the original parts.
Be sure that the threaded portions are clean and the bolts are correctly installed. This will prevent
damage to the bolts to the bolts when same are tightened. Lock nuts (not bolts!) with plastic layer or
steel nuts with flange have to be pulled up to app. 50 % of the value indicated in the table for “dry”
bolts. Toothed or castellated nuts have to be tightened to full torque.
* “Oiled”means that the bolts are provided with a lubricant such as engine oil or that bolts with
phosphate coating or oiled bolts are used. “Dry”means that the unlubricated standard or galvanized
bolts are used.
38 Maintenance and inspection C 1200
Daily • remove husk and stem residues and earth from cutting disc and the
maintenance working range of the intake drums
• Check the cleaners for the knives under the feed mechanism (see
fig. 27). Blunt or incorrectly positioned cleaners will cause blockages
and expose the drive mechanism to unnecessary load.
• Grind the knives of the flywheel cutting disc several times a day.
• Check the M12 attaching bolts of the cutting knives using a torque
wrench. Correct tightening torque:
130 Nm
Note: The standard tightening torques of 70 Nm will not be sufficient.
• Adjust the cutting disc centrally in relation to the shear bar.
• Even the knives have not been sharpened, the flywheel cutting disc
has to be readjusted twice a day.
• Check all knives under the feed mechanism, especially after a
foreign object has been encountered.
• Visual control of the parallelism of shear bar and cutting knives.
• Lubricate the implement in accordance with the greasing chart.
• Retighten all screws and bolts.
• Retighten the wheel studs.
Weekly • Retighten all attaching bolts of the cutting disc.
maintenance • Check the shear bar of the cutting disc. Reverse the shear bar if
necessary.
• Check the pivot and the angle drive.
• Lubricate the implement in accordance with the greasing chart.
Annual • Clean the machine and treat it with an anticorrosive agent.
maintenance • Change the oil in the gearboxes – observe the oil quantity laid down
by the manufacturer.
• Check all components for wear.
• Order genuine spare parts in time.
• Check the V-belt drive and the pivot.
• Check the overload clutches of the PTO shaft.
• Check all hydraulic lines and couplers.
• Check the complete housing with feed- and precompression rollers.
Maintenance and • Read the operators manual again.
controls before • Grease all parts of the machine with required lubrication.
start of season • Retighten all screws and bolts-
• Check the knives under the feed mechanism, the knives of the
flywheel cutting disc and the shear bar.
• Tightening torques:
Special knife attaching bolt with
knurled bottom of the bolt head: M12 = 130 Nm
Standard bolts: M12 = 70 Nm
M16 = 180 Nm
M 18 = 250 Nm
M20 = 360 Nm
• Check feed assisters on the intake drum and the divider points and
replace if necessary.
• Foreign objects may cause damage or deformations in the area
where the stems are cut. It is therefore essential to check this area
periodically. Straighten deformed feed tines Z (see fig. 53).
38 Maintenance and inspection C 1200
38 Maintenance and inspection C 1200
Intake drum Check the bearings and the attaching bolts of the large intake drum.
Cutting knives Check state, sharpness and positioning of the knives and the cleaners. To
avoid imbalance always replace opposite knives or cleaners by pairs.
Support wheel Tightened wheel studs periodically.
Feed mechanism Check the state of pecompression rollers, feed rollers and bearings.
NOTE: The stripper bar on the rear smooth roller must always be located
close to the roller without impairing its rotation.
Shear bar Remember that your forage harvester is a maxi-output machine which
should be kept in good condition at all times. Because of most of the power
is required by the chopping unit, the position of the shear bar should be
checked daily.
Flywheel cutting Safe operation of the flywheel cutting disc can be only ensured if the contact
disc surface of the knives is clean and the attaching bolts are pulled up to the
correct torque. Operate the forage harvester with sharp and undamaged
knives only. This will ensure a good chopping quality and keeps power
requirement low. Readjust the flywheel cutting disc centrally!
Hydraulic system Make certain that all hoses and couplers are in good condition.
The V-belt drive The V-belt drive (fig. 30 A) includes a 3 HB power band belt which is held at
the correct tension by means of a pressure spring 12. When installing the
belt the spring has to be set to the correct tension.
Hydraulically Before operating the machine check the function of the hydraulically
slewable discharge slewable chute. Sudden blockades can be caused by a grain of sand which
chute has plugged the restrictor 74, fig. 54 (both sides).
38 Maintenance and inspection C 1200
38 Maintenance and inspection C 1200
Pivoted mowing A common pivot connects the mowing attachment and the housing of the
attachment precompression rollers to the chopping unit. Both units can therefore be
swung to the side for repair or maintenance work (see fig. 55).
Do not allow anyone to stay in the slewing range of the machine. Check that
the machine is in a horizontal position when swinging round. Failure to do so
may cause the machine to swing round due to its weight when the locking
mechanism is released. Special care should be taken when operating on a
slope.
Fold up the guard and unhook the pressure springs 1 & 2 (fig. 55).
The mowing attachment / intake drum can also be swung round separately.
To this end slacken spring 12 and remove power band 11 from roller 13.
When reassembling the unit make certain that the power band is at the
correct tension. Tension will be correct when spring 12 is compressed to 270
mm (measured between both eyelets).
Cleaners (fig. 57) The cleaners fitted above the teeth of the feed drum have the important task
of constantly clearing husk accumulations on the scrapers. There should be
a maximum distance of 1 – 2 mm between cleaner and scraper edge.
The cleaners are made from highly resistant special steel. Since they are
constantly suffering from wear it is essential to check them periodically.
Accumulations of husks indicate that the cleaners are poorly adjusted or
defective. Worn cleaner tips can be repaired by build-up welding with steel
electrodes.
40 Electric circuit diagram C 1200
44 Troubleshooting C 1200
59
46 Spare parts C 1200