KUHN ALTERNA 400 Operator's Manual
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KUHN ALTERNA 400 Operator's Manual

KUHN ALTERNA 400 Operator's Manual

Mower conditioner
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OPERATOR'S MANUAL
KN084EGB E
Mower conditioner
- English - 11-2009
KN084EGB E

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  • Page 1 OPERATOR'S MANUAL KN084EGB E Mower conditioner - English - 11-2009 KN084EGB E...

  • Page 3: Dear Owner

    Designated use of the machine The ALTERNA 400 mower conditioner must only be used for the work for which it has been designed: mowing on the ground of hay fields, grass silage fields and improved pastures for the purpose of harvesting fodder for feeding livestock.

  • Page 4: Table Of Contents

    Mower conditioner ALTERNA400 $Contents Dear Owner ........................1 Contents .........................2 Identification of the machine..................4 Front view............................4 Model identification plate ........................5 Optional equipment..........................5 Safety..........................6 Description of symbols used in this document................6 Safety instructions ...........................7 Location and description of safety decals on the machine ............15 Road safety equipment and recommendations................18 Machine specifications ....................20 Description and glossary.......................20...
  • Page 5 Mower conditioner ALTERNA400 Instructions for work ....................44 Putting the machine into work position ..................44 Adjustments in working position....................45 Machine use............................ 50 Optional equipment ..................... 53 Yokes............................... 53 Maintenance and storage.................... 54 Frequency chart ..........................54 Lubrication............................55 Maintenance............................

  • Page 6: Identification Of The Machine

    Mower conditioner ALTERNA400 $Identification of the machine 1. Front view Identification of the machine...

  • Page 7: Model Identification Plate

    Mower conditioner ALTERNA400 2. Model identification plate Please write below the type and serial number of the machine. This information is to be indicated to the dealer for all spare parts orders. FC400 Type: Serial no.: 3. Optional equipment Part no. 4503710: 1 3/8’’ - 6 spline yoke. Part no.

  • Page 8: Safety

    Mower conditioner ALTERNA400 $Safety 1. Description of symbols used in this document This symbol indicates a potentially hazardous situation that if not avoided, could result in serious bodily injury. This symbol is used to identify special instructions or procedures which, if not followed strictly, could result in machinery damage.

  • Page 9: Safety Instructions

    Never let anyone operate the machine who is not trained to do so. Should you have any difficulties in understanding certain parts in this manual, please contact your KUHN dealer. Precautions to be taken before carrying out any operations on the machine...
  • Page 10 Mower conditioner ALTERNA400 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.
  • Page 11 Mower conditioner ALTERNA400 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.
  • Page 12 Mower conditioner ALTERNA400 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.
  • Page 13 Mower conditioner ALTERNA400 PTO shaft Use only PTO shafts supplied with the machine or recommended by the manufacturer. The protective shield of the tractor PTO stub, the PTO shaft guards and the protective covering of the machine input shaft must always be in place and in good condition.
  • Page 14 Mower conditioner ALTERNA400 Precautions during manoeuvres When moving the machine from the transport position to the working position and vice versa, make sure that nobody is within the machine pivoting area. Remote controlled components Danger of crushing and shearing can exist when components are operated by hydraulic or pneumatic controls.
  • Page 15 For your own safety and for correct machine operation, only use original manufacturer parts. It is strongly recommended to have your machine checked by your Kuhn dealer after each season, especially tools and their attaching hardware. Projection of stones and foreign objects For driver safety, always use a tractor equipped with a cab.
  • Page 16 Mower conditioner ALTERNA400 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.

  • Page 17: Location And Description Of Safety Decals On The Machine

    Mower conditioner ALTERNA400 3. Location and description of safety decals on the machine Location of safety decals Safety...
  • Page 18 Mower conditioner ALTERNA400 Description of safety decals Operating instructions (1) The operators' manual contains all the information necessary for using the machine safely. It is imperative to read and comply with all instructions. Working on the machine (2) Before leaving tractor before adjusting,...
  • Page 19 Mower conditioner ALTERNA400 Rotating cutting tools (5) Keep away from the mower knives all the time the engine is running, the PTO drive engaged and the moving parts have not come to a complete stop. Cutting tools (6) The cutting tools and their attachment hardware meet safety and reliability criteria set by standards and by the manufacturer.

  • Page 20: Road Safety Equipment And Recommendations

    4. Road safety equipment and recommendations The road safety equipment is mounted in the factory or by your authorized Kuhn dealer according to current safety regulations. Always keep to the legal speed limit for driving a tractor-machine assembly on public roads.
  • Page 21 Mower conditioner ALTERNA400 Tyre pressure Transport wheel tyre pressure: - (a): 3 bar (44 psi). - (b): 4 bar (58 psi). Work wheel tyre pressure: - (c): 1.8 bar (25 psi). Instructions specific to France Speed Always keep to the legal speed limit of 25 km/h for driving a tractor-machine assembly on public roads.

  • Page 22: Machine Specifications

    Mower conditioner ALTERNA400 $Machine specifications 1. Description and glossary Drawbar Check chains Parking stand Wheel chocks Cutterbars Side guards Front guards Drawbar shift cylinder Primary PTO shaft 10 : Handbrake Machine specifications...
  • Page 23 Mower conditioner ALTERNA400 Transport wheels Work wheels Secondary PTO shaft Toolbox Swath shields Machine specifications...

  • Page 24: Technical Specifications

    Mower conditioner ALTERNA400 2. Technical specifications Attachment type 2 point linkage category 2 and 3 Number of discs Working width 3.90 m (12’10’’) Width in working position 6.54 m (21’5’’) Height in working position 1.60 m (5’3’’) Length in working position 5.93 m (19’5’’) Width in transport position 2.50 m (8’2’’)

  • Page 25: Required Equipment

    Mower conditioner ALTERNA400 3. Required equipment Braking system This equipment is fitted on the machine transport wheels, in conformity with the legislation in force in the country concerned. 3 possibilities: Without actuation system. hydraulic actuation system. The equipment is composed of: - 3 hydraulic hoses (1).

  • Page 26: Sound Levels

    Mower conditioner ALTERNA400 4. Sound levels Sound levels have been measured in accordance with the measuring methods as defined in: NF EN 1553 "Agricultural machinery - Self-propelled, mounted, semi-mounted and trailed - Common safety recommendations" Weighted equivalent continuous acoustic pressure level at the driver's seat (closed cabin) L (A) eq: Tractor only: 76.7 dB(A) Tractor + machine: 77.8 dB(A) Machine specifications...

  • Page 27: Putting Into Service

    Mower conditioner ALTERNA400 $Putting into service 1. Description of control elements The machine is supplied with an 18 mm box wrench (1) to carry out certain adjustment and maintenance tasks. The machine is fitted with one electric control handle (1). The control handle changes the function of the tractor's double acting valve and enables: - Pivot drawbar to mow to the tractor left or right.
  • Page 28 Mower conditioner ALTERNA400 Description of the connection Never connect battery charger or perform welding tasks without having previously disconnected the control box. The control handle is to be pluged into a 3-pin socket. For tractors not fitted with a 3-pin socket, a wiring harness to be connected directly to the battery is delivered with the machine.

  • Page 29: Coupling And Uncoupling

    Mower conditioner ALTERNA400 2. Coupling and uncoupling Description of coupling elements - A PTO shaft 1 3/8’’ - 6 splines (1). - 2 check chains (2). - 2 hoses to control the mowing unit raising or lowering (3). - Two hydraulic hoses controlling the drawbar shift cylinder (4).
  • Page 30 Mower conditioner ALTERNA400 Preparing the tractor The machine adapts to tractors fitted with a 3-point hitch coupler category 2 or 3. The tractor must be fitted with lower link stabilizers. The tractor PTO stub must rotate at a speed of 1000 min The tractor must be equipped with: - 2 double acting hydraulic outlet.
  • Page 31 Mower conditioner ALTERNA400 Coupling the machine - Lower the tractor three-point linkage. - Place the lower links as close as possible under the hitch pins. - Attach lower links to the hitch pins on the inside of the yokes. • Category 2 (a) •...
  • Page 32 Mower conditioner ALTERNA400 When the machine is fitted with a brake actuation system Unlock handbrake. Putting into service...
  • Page 33 Mower conditioner ALTERNA400 Hydraulic connections Connect the 2 hydraulic hoses of the drawbar shift cylinder to a double acting valve (1). Connect mowing unit lift cylinder hoses to a double acting valve (2). Connect hydraulic hose for braking system to the tractor "trailor brake"...
  • Page 34 Mower conditioner ALTERNA400 Electrical connections - Connect 7-pin plug to the tractor. Fit check chain See section "Frame height adjustment" to position the check chain. Parking brake cord When the machine is fitted with a brake actuation system: - Attach coupling disconnection cord to a fixed point on the tractor.
  • Page 35 Mower conditioner ALTERNA400 Primary PTO shaft Friction slip clutch The machine is fitted with a friction slip clutch. Before the machine is put into service and after a long period of non-use, check the function of slip clutch to ensure it is not locked up.
  • Page 36 Mower conditioner ALTERNA400 PTO shaft Make sure that the PTO shaft is correctly adjusted, to avoid premature wear and tear. Separate the two half PTO shafts and connect them to the machine's friction slip clutch and to the tractor PTO stub.
  • Page 37 Mower conditioner ALTERNA400 Attach PTO shaft guard chain in hole (1) on machine side. Immediately replace any worn or damaged guard. Putting into service...
  • Page 38 Mower conditioner ALTERNA400 Adjusting the machine Lateral adjustment of the lower links. Balance the play on either sides of the lift linkage and lock lower link stabilizers. Frame height and check chains - Lower tractor lift linkage until hitch pins are at a distance (H) slightly over 650 mm (2’1’’) from the ground.
  • Page 39 ALTERNA400 Adjusting the braking system The braking system is mounted and adjusted either at the factory or by your Kuhn dealer. No adjustment is required. Contact your Kuhn dealer for any service operation. Adjustment of the stroke end sensor for...
  • Page 40 Mower conditioner ALTERNA400 Drawbar pressure pad adjustment The screw (1) must be in contact with pressure pad (2) without blocking it. Tighten counter nut (3): - Torque: 5 daN m (37 lbf ft). Proceed the same way on the other side. Adjustment of the stroke end sensor for rear transport wheel position Operate drawbar shift cylinder to pivot and position...
  • Page 41 Mower conditioner ALTERNA400 Uncoupling the machine Park the machine on an even fairly level ground. Preferably park the machine in transport position. From the transport position: - Pull handle (1). - Lower and lock parking stand (2). - Remove and store check chains. - Lower the tractor three-point linkage to rest the machine on the ground.
  • Page 42 Mower conditioner ALTERNA400 When the machine is fitted with a brake actuation system: - Apply parking brake (a). - Remove cord from tractor and store it in its holder on the machine. - Disconnect the PTO shaft from the tractor. Secure primary PTO shaft using safety chain (1).

  • Page 43: Instructions For Transport

    Mower conditioner ALTERNA400 $Instructions for transport Before placing the machine into transport position: - Place the machine on level ground. - Wait until the rotating parts have come to a complete stop. - Check that nobody is within the machine pivoting area.
  • Page 44 Mower conditioner ALTERNA400 - Operate drawbar shift cylinder to pivot and place the machine under the drawbar. - Check that the mowing units are latched underneath the drawbar. - Operate mowing unit lift cylinders to fully raise work wheels. - Disconnect and place hydraulic hose couplers in their holders.

  • Page 45: Conformity With The Road Regulations

    Mower conditioner ALTERNA400 2. Conformity with the road regulations Before driving the machine on public roads, ensure that the machine complies with current highway code regulations. Check that the light boards are clean and that the lighting equipment functions before transporting the machine on public roads.

  • Page 46: Instructions For Work

    Mower conditioner ALTERNA400 $Instructions for work Before placing the machine in working position: - Check that nobody is within the machine pivoting area. - If there is someone, make sure the person moves away. 1. Putting the machine into work position From the transport position: - Connect the 2 hydraulic hoses of the drawbar shift...

  • Page 47: Adjustments In Working Position

    Mower conditioner ALTERNA400 2. Adjustments in working position Cutting height Place the machine on flat ground. The cutting height is adjusted with the machine attached, hitch pins 650 mm (2’1’’) from the ground. To adjust the cutting height: - Adjust central skid. - Replace side skids.
  • Page 48 Mower conditioner ALTERNA400 Replacing the side skids The machine is factory set with low skids. Additional skids are supplied with the machine: Side skids Cutting height Lower 30 mm (1.2’’) Middle 40 mm (1.6’’) Raised 80 mm (3.2’’) - Remove the 4 nuts (2). - Remove 4 bolts (1).
  • Page 49 Mower conditioner ALTERNA400 Reduced or increased ground pressure Place the machine on flat ground. The cutting height is adjusted with the machine attached, hitch pins 650 mm (2’1’’) from the ground. To check the ground pressure From the working position: - Check that chassis...
  • Page 50 Mower conditioner ALTERNA400 Conditioning intensity Operate mowing unit lift cylinder to lower the mowing units on the ground. Before leaving tractor 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.
  • Page 51 Mower conditioner ALTERNA400 Selecting the conditioning surface of the comb The comb can be turned over to modify the conditioning intensity: - A more aggressive side for gramineous plants. - A softer side for more delicate varieties. Adjustment: - Remove 2 bolts (1). - Slide pin (2).

  • Page 52: Machine Use

    Mower conditioner ALTERNA400 3. Machine use Before mowing and to reduce risks of projections, lower front guards. Check that nobody is within the machine pivoting area. Keep all persons and animals away from the machine danger zone. Never lean or step on the guards. In case an obstacle has been struck, check that the mowing unit has not been damaged.
  • Page 53 Mower conditioner ALTERNA400 Working "back and forth" First pass - Operate drawbar shift cylinder to put the drawbar in working position (a). - Make first pass. Second pass - Operate drawbar shift cylinder to position drawbar on the other side (b). Instructions for work...
  • Page 54 Mower conditioner ALTERNA400 Work "around the field" Instructions for work...

  • Page 55: Optional Equipment

    Mower conditioner ALTERNA400 $Optional equipment 1. Yokes Additional yokes are available for the primary PTO shaft: 1 3/8’’ - 6 spline yoke Part no. 4503710 1 3/4’’ - 6 spline yoke Part no. 4503712 1 3/4’’ - 20 spline yoke Part no.

  • Page 56: Maintenance And Storage

    Mower conditioner ALTERNA400 $Maintenance and storage Before leaving tractor 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. 1.

  • Page 57: Lubrication

    Mower conditioner ALTERNA400 2. Lubrication Except for the secondary PTO shaft lubrication, the machine must be placed in transport position for all maintenance operations (knife replacement, lubrication, etc). Clean grease nipples before greasing. Lubricate with SHELL multi-purpose grease grade NLGI 2. PTO shaft Primary PTO shaft - Every 20 hours:...
  • Page 58 Mower conditioner ALTERNA400 Secondary PTO shaft - Every 20 hours: • universal joints (1). • transmission tube (2). - Every 100 hours: • guide rings (3). The pictorials show the points to be greased (1). Maintenance and storage...
  • Page 59 Mower conditioner ALTERNA400 Draining the cutterbars Before draining oil, operate the machine for a few minutes so that the oil warms up. The cutterbar is lubricated with 1.4 L (0.37 US gal) of SHELL SPIRAX A extreme-pressure gear oil with viscosity grade SAE 80W90 and API grade GL5.
  • Page 60 Mower conditioner ALTERNA400 Central gearbox draining Before draining oil, operate the machine for a few minutes so that the oil warms up. The angle gearbox is lubricated with 5.75 L (1.52 US gal) of SHELL SPIRAX A extreme-pressure oil for mechanical transmissions with viscosity grade SAE 80W90 and API grade GL5.
  • Page 61 Mower conditioner ALTERNA400 Draining the Gyrodine gearbox Before draining oil, operate the machine for a few minutes so that the oil warms up. The Gyrodine gearbox is lubricated with 5.5 L (1.42 US gal) of SHELL SPIRAX extreme-pressure gear oil with SAE 80W90 viscosity grade API and GL5. When draining and refilling, it is recommended to use either a mineral base oil with viscosity grade SAE 80W90 and API grade GL5, or a synthetic base oil, type PAO (Poly-Alpha-Olefins) with a viscosity grade equivalent to SAE 80W90.
  • Page 62 Mower conditioner ALTERNA400 Changing angle gearbox oil Upper gearbox: Before draining oil, operate the machine for a few minutes so that the oil warms up. The upper gearbox is lubricated with 1.75 L (0.46 US gal) of SHELL SPIRAX extreme-pressure gear oil with SAE 80W90 viscosity grade API and GL5.
  • Page 63 Mower conditioner ALTERNA400 Lower gearbox: Before draining oil, operate the machine for a few minutes so that the oil warms up. The lower gearbox is lubricated with 1.75 L (0.46 US gal) of SHELL SPIRAX extreme-pressure gear oil with SAE 80W90 viscosity grade API and GL5. When draining and refilling, it is recommended to use either a mineral base oil with viscosity grade SAE 80W90 and API grade GL5, or a synthetic base oil, type PAO (Poly-Alpha-Olefins) with a viscosity grade equivalent to SAE 80W90.
  • Page 64 Mower conditioner ALTERNA400 Grease - Pivot points (1). - Pivot point (1). - Ball joints (1). - Chain (2). - Pin (1). Proceed the same way on the other side. Maintenance and storage...
  • Page 65 Mower conditioner ALTERNA400 - Pressure pads (1). From the transport position. Grease: - Wheel arms (1). Maintenance and storage...

  • Page 66: Maintenance

    Mower conditioner ALTERNA400 3. Maintenance Before leaving tractor 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. After the first 10 hours of use Belts Check belt tension...
  • Page 67 - (Part no. 83101696). Braking system The braking system is mounted and adjusted either at the factory or by your Kuhn dealer. No adjustment is required. Contact your Kuhn dealer for any service operation. Maintenance and storage...
  • Page 68 Mower conditioner ALTERNA400 Checking cutterbar oil level Periodically check the cutterbar oil level: - Park the machine on an even fairly level ground. - Remove filler plug (1) and (2) as well as their seals. - Through filler plugs, check that the oil level (h) is comprised between 7 and 8 mm (0.27’’...
  • Page 69 Mower conditioner ALTERNA400 Checking the oil levels Gyrodine gearbox - Check oil level in lower gearbox: • The "MAX" level corresponds to the mark on the dipstick plug. • The "MIN" level corresponds to the end of the dipstick plug. Side gearbox - Check angle gearbox oil level: •...
  • Page 70 Mower conditioner ALTERNA400 Inspection of knives and securing elements Immediately replace worn or damaged parts with genuine KUHN parts. Knives Inspect systematically all knives before the machine is operated to: • guarantee the cutting quality. • guarantee safety in use.
  • Page 71 Mower conditioner ALTERNA400 Fixing elements Check the fixing elements: - After hitting an obstacle. - When replacing knives. - At the beginning of each season. The fixing bolts should be changed in the following cases: - When there is visible distortion. - When the locking compound is worn or inoperational.
  • Page 72 Mower conditioner ALTERNA400 Knife replacement Replace knife lock-nuts and bolts when they have been removed 5 times. Replace immediately all worn or distorted knives. Never straighten a bent knife. Always replace both knives per disc. Clean the nut case. Place a wooden wedge between two discs to stop them from rotating.
  • Page 73 Mower conditioner ALTERNA400 Drawing of the hydraulic circuit Maintenance and storage...

  • Page 74: Storage

    Mower conditioner ALTERNA400 4. Storage At the end of each season - Clean the machine thoroughly. - Drain all gearboxes and cutterbar and refill with new oil (see "Lubrication" chapter). - Touch up any areas of damaged paintwork. - Put the machine under cover in a dry place. - Inspect and replace worn knives and bolts (See section: Inspection of knives and securing elements).

  • Page 75: Trouble Shooting Guide

    Mower conditioner ALTERNA400 $Trouble shooting guide Problem Cause Remedy Too low PTO speed (rotational Increase speed to 1000 min frequency). Dull or broken knives. Replace knives. Make sure the arrow on the Knives not installed correctly. knife upper face is pointing in Uneven stubble.
  • Page 76 Mower conditioner ALTERNA400 Check the rotor drive belts, Belts slip. replace if necessary. Too low PTO speed (rotational Increase speed to 1000 min frequency). Badly shaped windrows. Excessive ground speed. Reduce ground speed. Adjust combs according to grass Comb angle not adapted. condition.

  • Page 77: Limited Warranty

    Mower conditioner ALTERNA400 $Limited warranty Limited warranty...
  • Page 78 Mower conditioner ALTERNA400 Limited warranty...

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