KUHN ALTERNA 400 Manuel utilisateur

ASSEMBLY / OPERATORS MANUAL

MOWER CONDITIONERS

ALTERNA 400 / 400 R & 500 / 500 R

No 95105 D.GB - 01.2002

DEAR OWNER,

In buying a KUHN machine you have chosen wisely. Into it have gone years of thought,

researchandimprovements.Youwillfind,ashavethousandsofownersallovertheworld,that

you have the best that engineering skill and actual field testing can produce. You have

purchased a dependable machine, but only by proper care and operation can you expect to

receive the performance and long service built into it.

This manual contains all the necessary information for you to receive full efficiency from your

machine.Theperformanceyougetfromthismachineislargelydependantuponhowwellyou

readandunderstandthismanualandapplythisknowledge.PleaseDONOTASSUMETHAT

YOU KNOW HOW TO OPERATE AND MAINTAIN YOUR MACHINE before reading this

manual carefully. KEEP THIS MANUAL AVAILABLE FOR REFERENCE.

YourKUHN dealerwillinstruct youonthegeneral operationofyourmachine. He isinterested

that you get the best performance possible and will be glad to answer any special questions

that may arise regarding the operation of the KUHN machine.

Your KUHN dealer can offer a complete line of genuine KUHN service parts.

These parts are manufactured and carefully inspected in the same factory that builds the

machine to assure high quality and accurate fitting of any necessary replacements.

When ordering service parts it is important that you indicate the type of machine concerned

and its serial number.

Forthisreasonpleasecompletethemodelidentificationplatediagrambelowwiththerequired

information. This will provide you with an easy reference for future service parts orders.

ABOUT IMPROVEMENTS

KUHN iscontinuallystriving to improveitsproducts and,therefore,reserves the righttomake

improvements or changes when it becomes practical to do so, without incurring any

obligations to make changes or additions to the equipment sold previously.

- 1 -

CONTENTS

Page

Safety notices 2 - 7

Safety decals 8 - 9

Technical specifications 10

Assembly instructions 11

Attachment to the tractor 12 - 13

Detaching the machine 14

Transport to work position 15 - 16

Work to transport position 17 - 18

Adjustments 19 - 25

Securingdiscsand knives 27

Inspection ofknives &securing elements 28 - 29

Importantrecommendations 30

Lubrication 31 - 36

Optionalequipment 36

Storingthemowerconditioner 37

TroubleShootingGuide 38 - 39

Hydraulicschematic 40

Electric lay out, connections and schematic 41

Seven-conductorelectricalconnector(forNorthAmerica) 42

Limitedwarranty 43 - 44

- 2 -

SAFETY

Thesymbolaboveisusedthroughoutthismanualeverytimerecommendationsaremadeconcerningyoursafety,

the safety of others, or the good operation of the machine.

Theserecommendationsmust be made known to all machine operators.

DESIGNATED USE OF THE MACHINE

TheALTERNAmowerconditionersmustonlybeusedfortheworkwhichtheyhavebeendesigned:mowingonthe

ground of hay fields, grass silage fields and improved pastures for the purpose of harvesting fodder for feeding

livestock.

Themanufacturerisnotheldliableforanydamageresultingfrommachineapplicationsotherthanthosespecified

bythemanufacturer.

Any use other than the designated operation is at the risk and responsibility of the operator.

Designated use of the machine also means :

-followingoperation,maintenanceandrepairrecommendationsgivenbythemanufacturer;

-using only genuinespare parts, equipmentand accessories asdesignated by themanufacturer.

TheALTERNAmowerconditionersmustonlybeoperated,maintainedandrepairedbycompetentpersonswhoare

familiarwithmachinespecificationsandoperationandareawareofanydangerinvolved.

Theoperatormustimperativelyrespectcurrentlegislationconcerning:

-accidentprevention,

- work safety,

-public traffic circulation.

All safety advice indicated on the machine must be strictly observed.

Themanufacturerisnotheldliableforanydamageresultingfrommachinemodificationscarriedoutbytheoperator

himselforbyathirdpartywithoutpreviouswrittenagreementfromthemanufacturer.

- 3 -

GENERAL SAFETY RECOMMENDATIONS

Beforeoperatingthemachine,alwaysensurethattractorandmachineareinaccordancewithworksafetyandroad

trafficregulations.

BASIC PRINCIPLES

1. Inadditiontotherecommendationsgiveninthismanual,legislationonworksafetyandaccidentpreventionmust

alsobe respected.

2. Adviceis indicatedonthe machine, specifyingsafetyrecommendations in ordertoprevent accidents.

3. Beforetravellingonpublicroads,theoperatormustensurethatthemachineconformstoroadtrafficregulations.

4. Before starting work, the operator must be familiar with all machine controls, handling devices and their

functions. Once at work, it is too late to do so !

5. Thetractormustbeequippedwithasafetycab.Keepwindowsandroofhatchclosedforreducedsoundlevel

whileoperatingthePTOdrivenimplement.

6. Beforestartingupthemachineandbeginningwork,checkthesurroundingarea(bewareofchildren!).Make

surethereissufficientvisibility.Keepallpeopleandanimalsawayfromthedangerzoneofthemachine(risk

ofprojection!)

7. Carryingpeople oranimals on themachine when working orin transport isstrictly forbidden.

8. Machine must only be attached to tractor using means provided and in accordance with current safety

standards.

9. Whenattaching or removing themachine, placetheparkingstandinto the corresponding position.

10. Special careshouldbetaken when attaching orremovingthe machine from thetractor.

11. Before attaching themachine,makesure that the maximum permittedfrontaxleweightand gross weight of

thecombination are not exceeded.

12. Do notsurpassthe maximum permittedlengthand width authorizedbyroad traffic regulations.

13. Do notsurpassthe maximum transportwidthauthorized by road trafficregulations.

14. Beforetransportingthemachineonpublicroads,ensurethatalllegallyrequiredguardsandindicators(lights,

reflectors...) are in place andin good operation.

15. All operating controls (cords, cables, rods ...) must be positioned so that they cannot be set off accidently,

riskingaccidentor damage.

16. Beforetransportonpublicroads,locatethemachineintoitstransportpositionasinstructedinthisoperator’s

manual.

17. Never leavethetractorseat whilethemachineis operating.

18. Drive speed must be adapted to ground conditions as well as roads and paths.

Alwaysavoidabruptchangesofdirection.

19. Precisionsteering,tractoradherence,roadholdingandefficientbrakingareinfluencedbythetypeofimplement,

weight, ballast of front axle, ground or road conditions. It is therefore of utmost importance to be cautious in

everygivensituation.

- 4 -

20. Beparticularlycautiouswhenturningcorners,payingattentiontomachineoverhang,length,heightandweight.

21. Keep clear of the machine operating area.

22. WARNING ! Danger of crushing and shearing can exist when components are operated by hydraulic or

pneumaticcontrols.

23. Beforeleavingthetractororbeforeadjusting,maintainingorrepairingthemachine,turnofftheengine,remove

ignition key and wait until all moving parts have come to a complete stop.

24. Donotstandbetweenthetractorandthemachineunlessthehandbrakeistightand/orstopshavebeenplaced

underthewheels.

25. Before anyadjustments,maintenanceor repairs are carriedout,ensurethat the machine cannotbestarted

up accidentally.

PRECAUTIONS TO BE TAKEN BEFORE OPERATING THE MACHINE

1. Do not wear loose clothing which could be caught up in moving parts.

2. Wear the individual protection equipment corresponding to the work which is planned (gloves, shoes, eye

protection,helmet,earprotectors...).

3. All operating controls (cords, cables, rods ...) must be positioned so that they cannot be set off accidentally,

causingaccident or damage.

4. Beforeoperatingthemachine, checkthetightnessofall nuts andbolts,particularlyonrotating parts(blades,

tines, knives, spades ...)

5. Beforeoperatingthemachine, ensurethatallsafety guards are firmly in place andin goodcondition. Ifworn

ordamaged,replaceimmediately.

ATTACHMENT

1. When attaching or removing themachine from the tractor, makesurethatitcannotmoveaccidentally.(Put

wedgesunderthewheels).

2. When attaching the machine to tractor hydraulic linkage, ensure that diameter of link pins corresponds to

diameter of ball joints.

3. WARNING ! Danger of crushing and shearing can exist in the lifting zone of the tractor hydraulic linkage !

4. Donotstandbetweenthetractorandthemachinewhenoperatingtheoutercontrolleveroftheliftmechanism.

5. Make sure that the weight applied to the tractor's draught arms does not go over the maximum weight

indicated by the manufacturer.

6. Make sure flexibility between tractor draught arms and machine drawbar is sufficient.

7. In transport, the tractor draught arms should be stabilized by the linkage to avoid stabilizer bars side to side

shifting.

8. Neveroperateortransportthemachinewithanarrowwheeltracktractor.

- 5 -

POWER TAKE-OFF

1. Only use PTO shaft supplied with the machine or recommended by the manufacturer.

2. PTO guards must always be in place and in good condition.

3. Check for correct PTO overlap when at work and in transport.

4. Beforeattachingor removingthePTOshaft, disengagePTOshaft,turn offengineandremoveignitionkey.

5. IfaprimaryPTOshaftisequippedwithaslipclutchorafreewheel,thesemustbefitted onthemachinePTO.

6. Ensure that PTO shaft is always correctly fitted and locked into place.

7. Make sure guards are correctly in place and secured with the safety chains provided.

8. Before engaging PTO, ensure that PTO speed (rotational frequency) and direction of rotation are in

accordancewithmanufacturer'srecommendations.

9. Before engaging PTO, keep all people and animals clear from the machine.

10. Never engage PTO shaft when tractor motor is turned off.

11. NeversurpassPTOanglerecommendedbythemanufacturer.

12. WARNING!RotatingelementscancontinueturningmomentarilyafterPTOisdisengaged.Keepclearuntil

all rotating elements are at a standstill.

13. When removing the machine, locate PTO shaft on the supports provided.

14. Fit safety cap on tractor PTO.

15. Replace any worn or damaged PTO guards immediately.

TIRES

1. Beforeanyworkisperformedonthewheels,ensurethatthemachinerestsonthegroundandisperfectlystable

so that it cannot move accidentally (put wedges in place).

2. Assembly, disassembly and repair of wheels and tires must only be carried out by competent persons who

are equipped with standardized tools.

3. Check tire pressure regularly !

Respect manufacturer’s recommendations on tire pressure.

Rotation speed ... rpm (American Measure) is also expressed in metric measure : Rotational frequency ... min-1.

Both units are equivalent, for example : Rotation speed 540 rpm equals Rotational frequency 540 min-1.

- 6 -

HYDRAULICSYSTEM

1. WARNING ! Hydraulic system is under pressure (maximum working pressure : 200 bars / 2900 psi).

2. When fitting hydraulic motors or cylinders, ensure that connections have been made correctly, as per

manufacturer’s instructions.

3. Before connecting hoses to the tractor hydraulics, ensure that tractor and machine circuits are not under

pressure.

4. It is strongly recommended that the operator marks the hydraulic connections between tractor and machine

to avoid making a wrong connection. WARNING ! Functions could be reversed (for example : lift/lower).

5. Regularly check the hydraulic hoses ! In case of normal wear, replace the hydraulic hoses every 5 years.

Damaged or worn hoses must immediately be replaced .

Whenreplacingthehydraulichoses,makesuretousehoseswiththespecificationsandqualityrecommended

bythe manufacturer of themachine.

6. Should a leak be found, take all necessary precautions to avoid accidents.

7. Any liquid under pressure (particularly oil from hydraulics) can penetrate the skin and cause severe injury. If

injured,see a doctor immediately,therecould be dangerofinfection.

8. Beforeany adjustments, maintenanceorrepairs are carried out,lowerthemachine, depressurize the circuit,

turn off the engine and remove ignition key.

MAINTENANCE

1. Before checking any machine malfunction and before adjusting, maintaining or repairing the machine,

disengage PTO, turn off engine and remove ignition key.

2. Check tightness of nuts and bolts regularly. Retighten if necessary.

3. If the machine is raised, prop it up in a stable position before carrying out any maintenance work.

4. When replacing a working part, wear protection gloves and only use standardized tools.

5. It is forbidden to discard any oil, grease or filters. These must be given to waste disposal organisations to

protect the environment.

6. Disconnect power source before any work is done on the electric system.

7. Check safety guards regularly, particularly those that are subject to wear. Replace immediately if damaged.

8. Spare parts used must be in accordance with specifications 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 generator and battery

terminals.

10.Repairs on elements under pressure or tension (springs, accumulators etc.) must only be carried out by

competent persons with standardized equipment.

- 7 -

SPECIAL SAFETY RECOMMENDATIONS

1. Use a tractor equipped with an enclosed cab with windows made of safety glass and kept closed. It is

recommendedtofitpolycarbonatescreensinsidethetractorsafetycab'ssideandrearwindowsortoinstall

mesh guards on the exterior of them.

2. Stay a safe distance away from the mower when discs are rotating.

3. Forsafemachineoperation,itisimperativethatcuttingtoolsbefittedinaccordancewiththemanufacturer’s

recommendations. Use only the tool outfit supplied with the machine.

4. Each time before using the mower, inspect condition of cutting elements (knives, discs). Replace any

missing, worn or damaged cutting elements immediately. Use only genuine KUHN spare parts.

5. To avoid creating dangerous out of balance forces, always replace missing, damaged or worn knives in

pairs.

6. When replacing knives or discs, systematically inspect their securing elements as per the manufacturer’s

recommendations.

7. Regularlyinspectthediscmower’sprotectioncover.Wornordamagedprotectioncoversmustbereplaced

immediately.

8. Protection devices (such as guards, shields etc.) are intended to prevent stones, rocks or other foreign

objects from being projected. They also prevent access to the machine’s danger zones. Therefore, it is

imperative that protection devices are put in place and properly secured each time before using the

machine.

9. Crushing and shearing zones which could cause serious bodily injury when changing the machine from

transport to work position and vice versa may exist. To prevent possible injury, be extra careful when

maneuvering and ensure that everyone is at a safe distance away from the machine.

10. Never tow the machine at speeds higher than 25 km/h (15 mph).

11. PTO drive to the mower must never be engaged unless the cutterbar skid shoes are in contact with the

ground and the protective cover is folded down.

12. Ground of the pastures to be mown must be free of foreign objects.

13. Even when the machine is used in accordance with it purpose, objects may be projected. It is therefore

imperative that everyone be kept away from the danger zone, that extra care be taken and that extra

precaution(suchassafetyindicators)betakenwhenmowingpasturesalongsideroadsornearpublicareas

(parks, schools etc.).

14. Never mow in reverse.

15. When disengaging the PTO drive, moving parts continue to rotate for some time. Wait for all moving parts

to come to a complete stop before approaching the machine.

16. If an obstruction is hit, stop the tractor immediately, disengage PTO drive, turn off engine, remove ignition

key and wait for all moving parts to come to a complete stop.

Check the entire machine for any damage before resuming work.

17. It is strongly recommended to have your machine checked by your dealer after each season, especially

blades and discs and their fixing devices (nuts, bolts etc.).

SAFETY DECALS

THEFOLLOWING SAFETY PICTORIALS HAVE BEENPLACEDONYOURMACHINEINTHEAREAS

INDICATED.THEYAREINTENDEDFORYOURPERSONALSAFETYANDFORTHESAFETYOFTHE

PEOPLE WORKING WITH YOU. THE TEXT SHOWN ON THEM GIVES THEIR PRECISE MEANING.

ENSURETHATTHESEPICTORIALS ARE ALWAYS LEGIBLE. IF THEYARENOT,REPLACETHEM.

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