KUHN ALTERNA 500R Operator's Manual
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KUHN ALTERNA 500R Operator's Manual

KUHN ALTERNA 500R Operator's Manual

Mower conditioner
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OPERATOR'S MANUAL
Mower conditioner
- English - 11-2005
KN086EGB C

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  • Page 1 OPERATOR'S MANUAL Mower conditioner - English - 11-2005 KN086EGB C...

  • Page 3: Dear Owner

    Designated use of the machine The ALTERNA 500R 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

    ALTERNA 500R $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............
  • Page 5 ALTERNA 500R Instructions for work....................44 Putting the machine into work position ..................44 Adjustments in working position ....................45 Machine use ........................... 50 Optional equipments....................53 Yokes .............................. 53 Maintenance and storage ....................54 Frequency chart..........................54 Lubrication ............................. 55 Maintenance ........................... 64 Storage ............................

  • Page 6: Identification Of The Machine

    ALTERNA 500R $IDENTIFICATION OF THE MACHINE 1. Front view Identification of the machine...

  • Page 7: Model Identification Plate

    ALTERNA 500R 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. FC500R Type: 3. Optional equipment Part no. 4503710: 1 3/8’’ - 6 spline yoke.

  • Page 8: Safety

    ALTERNA 500R $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 ALTERNA 500R 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-protectors, etc.). Make sure that all operating controls (ropes, cables, rods, etc) are placed so that they cannot be set off accidentally, risking accident or damage.
  • Page 11 ALTERNA 500R 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 transports of oversize equipment.
  • Page 12 ALTERNA 500R 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 ALTERNA 500R 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 ALTERNA 500R 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 ALTERNA 500R 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.

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

    ALTERNA 500R 3. Location and description of safety decals on the machine Location of safety decals Safety...
  • Page 18 ALTERNA 500R Description of safety decals Operating instructions (1) The operator's 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...
  • Page 19 ALTERNA 500R 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

    ALTERNA 500R 4. Road safety equipment and recommendations The road safety equipment is mounted in the factory or by your authorized dealer according to current safety regulations. Always keep to the legal speed limit for driving a tractor-machine assembly on public roads.
  • Page 21 ALTERNA 500R Tyre pressure Transport wheel tyre pressure: - (a): 3 bar (44 psi). - (b): 4 bar (58 psi). Work wheel tyre pressure: - (c): 1 bar (14 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

    ALTERNA 500R $MACHINE SPECIFICATIONS 1. Description and glossary Drawbar Check chains Parking stand Wheel chocks Cutterbars Side guards Front guards Primary PTO shaft Handbrake Machine specifications...
  • Page 23 ALTERNA 500R Transport wheels Work wheels Secondary PTO shaft Toolbox Swath shields Machine specifications...

  • Page 24: Technical Specifications

    ALTERNA 500R 2. Technical specifications Attachment type 2 point attachment category 2 and 3 Number of discs Working width 4.85 m (15’11’’) Width in working position 7.00 m (23’) Height in working position 1.60 m (5’3’’) Length in working position 5.36 m (17’7’’)

  • Page 25: Required Equipment

    ALTERNA 500R 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

    ALTERNA 500R 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)

  • Page 27: Putting Into Service

    ALTERNA 500R $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 ALTERNA 500R 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

    ALTERNA 500R 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 ALTERNA 500R 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 ALTERNA 500R 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 ALTERNA 500R When the machine is fitted with a brake actuation system Unlock handbrake. Putting into service...
  • Page 33 ALTERNA 500R 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 of braking system to the tractor "trailor brake"...
  • Page 34 ALTERNA 500R 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 ALTERNA 500R 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 ALTERNA 500R 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 ALTERNA 500R Attach PTO shaft guard chain in hole (1) on machine side. Immediately replace any worn or damaged guard. Putting into service...
  • Page 38 ALTERNA 500R 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...
  • Page 39 Adjusting the braking system The braking system is mounted and adjusted either at the factory or by your dealer. No adjustment is required. Contact your Kuhn dealer for any service operation. Adjustment of the stroke end sensor for right hand mowing position Drawbar shift cylinder The measure (X) is factory set at 557 mm (1’9’’).
  • Page 40 ALTERNA 500R 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.
  • Page 41 ALTERNA 500R 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.
  • Page 42 ALTERNA 500R 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. - Uncouple the PTO shaft from the tractor. Secure primary PTO shaft using safety chain (1).

  • Page 43: Instructions For Transport

    ALTERNA 500R $INSTRUCTIONS FOR TRANSPORT Before placing the machine into transport position: - Place the machine on flat horizontal ground. - Wait until the rotating parts have come to a complete stop. - Check that nobody is within the machine pivoting area.
  • Page 44 ALTERNA 500R - 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

    ALTERNA 500R 2. Conformity with the road regulations Before driving the machine on public roads, ensure that the machine meets current highway code regulations. Check that the signalling panels are clean and that the lighting equipment functions before going on public roads.

  • Page 46: Instructions For Work

    ALTERNA 500R $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...

  • Page 47: Adjustments In Working Position

    ALTERNA 500R 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.
  • Page 48 ALTERNA 500R 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).
  • Page 49 ALTERNA 500R 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...
  • Page 50 ALTERNA 500R Conditioning intensity Before adjusting, maintaining or repairing the machine, turn off ignition key and wait until all moving parts have come to a complete stop. Conditioning intensity is determined by the pressure exerted by the two rollers. pressure...
  • Page 51 ALTERNA 500R Check minimum gap between rollers: J = 2 à 3 mm (0.08’’ - 0.12’’) Readjust if necessary. Adjustment To increase the gap between the rollers: - Loosen counter nut (1). - Tighten nut (2) to increase gap between rollers.

  • Page 52: Machine Use

    ALTERNA 500R 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.
  • Page 53 ALTERNA 500R Working "back and forth" First pass - Activate 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).
  • Page 54 ALTERNA 500R Work "around the field" Instructions for work...

  • Page 55: Optional Equipments

    ALTERNA 500R $OPTIONAL EQUIPMENTS 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. 4503713...

  • Page 56: Maintenance And Storage

    ALTERNA 500R $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. 1. Frequency chart...

  • Page 57: Lubrication

    ALTERNA 500R 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.
  • Page 58 ALTERNA 500R 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 ALTERNA 500R Draining the cutterbars Before draining oil, operate the machine for a few minutes so that the oil warms up. The cutterbar is lubricated with 1.7 L (0.59 US gal) of SHELL SPIRAX extreme-pressure gear oil with viscosity grade SAE 80W90 and API grade GL5.
  • Page 60 ALTERNA 500R Central gearbox draining Before draining oil, operate the machine for a few minutes so that the oil warms up. angle gearbox lubricated with 5.75 L (1.52 US gal) SHELL SPIRAX extreme-pressure mechanical transmissions with viscosity grade SAE 80W90 and API grade GL5.
  • Page 61 ALTERNA 500R 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 6 L (1.58 US gal) of SHELL SPIRAX extreme- pressure gear oil with SAE 80W90 viscosity grade API and GL5.
  • Page 62 ALTERNA 500R Changing angle gearbox oil Upper gearbox: Before draining oil, operate the machine for a few minutes so that the oil warms up. upper gearbox lubricated with 1.75 L (0.46 US gal) SHELL SPIRAX extreme-pressure gear oil with SAE 80W90 viscosity grade API and GL5.
  • Page 63 ALTERNA 500R Lower gearbox: Before draining oil, operate the machine for a few minutes so that the oil warms up. lower gearbox lubricated with 1.75 L (0.46 US gal) SHELL SPIRAX extreme-pressure gear oil with SAE 80W90 viscosity grade API and GL5.
  • Page 64 ALTERNA 500R 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 ALTERNA 500R - Pressure pads (1). From the transport position. Grease: - Wheel arms (1). Maintenance and storage...

  • Page 66: Maintenance

    ALTERNA 500R 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. After the first 10 hours of use...
  • Page 67 Braking system The braking system is mounted and adjusted either at the factory or by your dealer. No adjustment is required. Contact your Kuhn dealer for any service operation. Roller gearbox The roller gearboxes are lubricated for life and do not require periodic maintenance.
  • Page 68 ALTERNA 500R 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 ALTERNA 500R 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 disptick plug. Side gearbox - Check angle gearbox oil level: •...
  • Page 70 ALTERNA 500R 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. • Prevent cutterbar damage risks.
  • Page 71 ALTERNA 500R 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 warping.
  • Page 72 ALTERNA 500R Knife replacement Replace knife lock-nuts and bolts when they have been removed 5 times. Replace systematically 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 ALTERNA 500R Drawing of the hydraulic circuit Maintenance and storage...

  • Page 74: Storage

    ALTERNA 500R 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). - Make all necessary paint touching ups. - Put the machine under cover in a dry place.

  • Page 75: Trouble Shooting Guide

    ALTERNA 500R $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 the disc's direction of rotation.
  • Page 76 ALTERNA 500R Increase the mowing unit ground Excessive floatation. pressure. ground contour Excessive ground speed. Reduce ground speed. adaptation. Incorrect tractor lift linkage Adjust height of lower links to setting. 650 mm (2’1’’) Slow response of the hydraulic Hydraulic oil filtering elements Clean filters if necessary.

  • Page 77: Limited Warranty

    ALTERNA 500R $LIMITED WARRANTY Limited warranty...
  • Page 78 ALTERNA 500R Limited warranty...

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