KUHN ALTERNA 400, ALTERNA 500R Operator's Manual
OPERATOR'S MANUAL
KN084EGB E
Mower conditioner
ALTERNA400
KN084EGB E
- English - 11-2009
Mower conditioner
ALTERNA400
$Dear Owner
In buying a Kuhn machine you have chosen wisely. Into it have gone years of thought, research and
improvement. You will find, as have thousands of owners all over the world, that you have the best that
engineering skill and actual field testing can produce. You have purchased a dependable machine, but only
through 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. The
performance you get from this machine is largely dependent on how well you read and understand th is manual
and apply this knowledge. Please DO NOT ASSUME YOU KNOW HOW TO OPERATE AND MAINTAIN YOUR
MACHINE before reading this manual carefully. KEEP THIS MANUAL AVAILABLE FOR REFERENCE. Pass
it on to the next owner if you re-sell the machine.
Your KUHN dealer can offer a complete line of genuine KUHN service parts. These parts ar e manufactured and
carefully inspected in the same factory that builds the machine to assure high quality and accurate fitting of any
necessary replacements.
About improvements
We are continually striving to improve our products. It therefore reserves the right to make improvements or
changes when it becomes practical to do so, without incurring any obligations to make changes or additions to
the equipment sold previously.
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.
Document illustrations
Most illustrations and photos pictured in this manual are based on a machine of type ALTERNA 500.
Dear Owner
1
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
Technical specifications............. ... ... ... .... ... ... ... ... .... ............................................. ... ... .... ... ............22
Required equipment.......................................................................................................................23
Sound levels ......... ... ... .... ... ... ... .... ............................................. ......................................................24
Putting into service......................................................................................................25
Description of control elements....................................................................................................25
Coupling and uncoupling..............................................................................................................27
Instructions for transport............................................................................................41
Putting the machine into transport position................................................................................41
Conformity with the road regulations...........................................................................................43
2
Contents
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....................................................................................................................................64
Storage............................................................................................................................................72
Trouble shooting guide...............................................................................................73
Limited warranty.......................................................................................................... 75
Contents
3
1. Front view
Mower conditioner
ALTERNA400
$Identification of the machine
4
Identification of the machine
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.
Mower conditioner
ALTERNA400
Type: FC400
Serial no.:
3. Optional equipment
Part no. 4503710: 1 3/8’’ - 6 spline yoke.
Part no. 4503712: 1 3/4’’ - 6 spline yoke.
Part no. 4503713: 1 3/4’’ - 20 spline yoke.
Identification of the machine
5
$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.
Mower conditioner
ALTERNA400
This symbol is used to identify special instructions or
procedures which, if not followed strictly, could result in
machinery damage.
This symbol is used to communicate technical
information of particular interest.
6
Safety
Mower conditioner
ALTERNA400
2. Safety instructions
Introduction
The machine must only be operated, maintained and repaired by competent persons who are familiar with
machines' specifications and operation and aware of safety regulations fo r preventing accidents.
The operator must imperatively respect safety instructions in this manual and in the warnings posted on the
machine. The operator is also obliged to respect current le gislation concerning accident prevention, wo rk safety
and public traffic circulation.
Designated use of the machine also means following operation, maintenance and repair recommendations
given by the manufacturer, and using only genuine spare parts, equipment a nd acce sso ries, as r ecom mended
by the manufacturer.
The manufacturer is not held liable for any damage resulting from machine applications other than those
specified by the manufacturer. Any use other than the designated operation is at the risk and responsibility of
the operator.
The manufacturer is not held liable for any damage or accident re sulting from machine modifications carried out
by the operator himself or by a third party without previous written agreement from the manufacturer.
Read and follow the safety instructions
Before using the machine, carefully read all the safety
instructions in this manual and the warnings placed on
the machine.
Before starting work, the operator must be familiar with
all machine controls, handling devices and their
functions. It is too late to learn once work has been
started!
Never let anyone operate the machine who is not traine d
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
Before leaving the tractor or 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.
Safety
7
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.
Before operating the machine, check tightness of nuts
and bolts, particularly on fixing elements (tines, forks,
blades, knives, etc). Retighten if necessary.
Before operating the machine, ensure that all the safety
guards are firmly in place and in good condition.
Immediately replace any worn or damaged guard.
Mower conditioner
ALTERNA400
Precautions when driving
Tractor handling, stability, performance and braking
efficiency are all affected by weight distribution, trailed or
mounted implements, additional ballast and driving
conditions. It is therefore of great importance that the
operator exercises caution in every given situation.
Groundspeed must be adapted to ground conditions as
well as to roads and paths. Always avoid abrupt change s
of direction.
Be particularly cautious when turning corners, paying
attention to machine overhang, length, height and
weight.
Never use a narrow track tractor on very uneven or
steeply sloping ground.
Never leave the tractor seat while the machine is
operating.
Carrying people or animals on the machine when
working or in transport is strictly forbidden.
8
Safety
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.
Gross weight and weight per axle
Check that the tractor's authorized gross weigh t as well
as its lift capacity and maximum weight per axle are not
exceeded.
The front axle load (1) must never, under any
circumstances, be less than 20% of the tractor's unladen
weight. If necessary, add ballast weights to the front or
to the rear to preserve the steering and braking
efficiency.
Mower conditioner
ALTERNA400
Transport position
Before transporting the machine on public roads, place
the machine into its transport position, according to the
instructions in this manual.
Lights and indicators
Before transporting the machine on public road s, ensure
that all legally required lightings and signallings are in
place.
Ensure that lightings and signallings are clean and in
good working order. Replace any missing or broken
equipment.
Always obey current regulations for driving
on roads.
Maximum speed
Always keep to the legal speed limit for driving a tractormachine assembly on public roads.
Safety
9
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.
Never stand between the tractor and the machine when
operating the three point linkage.
Do not stand between the tractor and the machine
without ensuring that the parking brake is applied.
Hydraulic circuit
Mower conditioner
ALTERNA400
Caution! The hydraulic circuit is under high pressure.
Maximum pressure at work: 200 bar.
Before connecting hoses to the tractor hydraulics,
ensure that tractor and machine circuits are not under
pressure. Before disconnecting a hose, depressurize the
hydraulic circuit.
To avoid making incorrect connections, mark hydraulic
couplers and corresponding hoses with colors.
WARNING! Functions could be reversed (for example:
lift/lower) and cause accidents.
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.
When replacing the hydraulic hoses, only use hoses with
the specification recommended by the manufacturer of
the machine.
To locate a leak, use appropr iate means. Protect body
and hands from liquid under pressure.
Any liquid under pressure (particularly oil from
hydraulics) can penetrate the skin and cause severe
injury. If injured, see a doctor immediately, there could
be danger of infection. Before any adjustments,
maintenance or repairs are carried out, lower the
machine to the ground, depressurize the hydraulics, turn
off the engine, remove ignition key and wait until all
moving parts have come to a complete stop.
10
Safety
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.
Make sure that the PTO shaft guards are se cured with
the safety chains provided.
Any worn or damaged guards must be replaced
immediately. A worn guard or an unprotected PTO shaft
can cause a serious or even a lethal accident.
Do not wear loose clothing that could be caught in the
rotating PTO shaft.
Before attaching or removing a PTO shaft, or before
doing any work on the machine, disengage the PTO
drive, turn off the engine, remove ignition key and wait
for all moving parts have come to a complete stop.
If the primary PTO shaft is equipped with a slip clutch or
a free wheel, these must be fitted on the machine side.
Ensure that the PTO shaft is always correctly fitted and
locked into place.
Before connecting the PTO shaft, ensure that the PTO
speed (rotational frequency) and directions of rotation
are in line with manufacturer's recommendations.
Before engaging the PTO drive, make sure all people
and animals are clear from the machine. Never engage
the PTO drive when the tractor engine is stopped.
When uncoupling the machine, rest the PTO shaft on the
support specially provided, and replace protective cover
on the PTO stub of the tractor.
Read and follow the instructions in the operator's ma nual
provided with the PTO shaft.
Mower conditioner
ALTERNA400
Safety
11
Precautions during manoeuvres
When moving the machine from the transport positio n 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. Keep away from these danger zones.
Tyres
Regularly check the tyre pressure. Respect
manufacturers' recommendations on pressure.
Assembly, disassembly and repair of wheels and tyres
must only be carried out by competent persons who are
equipped with standardized tools. Before any work is
performed on the wheels, ensure that the machine rests
on the ground and is perfectly stable so that it cannot
move accidentally (put chocks in place).
Mower conditioner
ALTERNA400
Safety decals
Safety warning decals are placed in pictorial form on
various parts of the machine. They are ther e to warn you
of potential dangers and to tell you how to avoid
accidents.
Always keep the safety decals clea n and readable, and
replace them when they are worn, damaged, missing or
illegible.
Waste disposal
Respect the environment! Never spill pollutants (oil,
grease, filters, etc.) on the ground, never pour them
down the drain and never discard them in any other
place where they could pollute the environment. Never
throw away or burn a tyre. Always take waste to
specialized recycling or waste disposal centers.
12
Safety
Precautions for maintenance and repair work
Before leaving the tractor or 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.
Rest the machine on the ground, release the pressure
from the hydraulic circuit and leave the machine to cool
down.
Make sure that the parts of the machine that need to be
lifted for maintenance or repair work are firmly propped
up.
Before any work is done on the electric circuit or before
any electric welding is carried out on the attached
machine, disconnect the machine from the tractor
electrical circuit. Also disconnect alternator and battery
terminals.
Repairs on elements under pressure or tension (springs,
pressure accumulators, etc.) must only be carried out by
competent persons with regulation equipment.
Wear the appropriate protective clothing for the work in
hand (gloves, shoes, goggles, helmet, ear defenders,
etc.).
Do not solder, weld or use a blow torch near fluids under
pressure or inflammable products.
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.
Mower conditioner
ALTERNA400
Projection of stones and foreign objects
For driver safety, always use a tractor equipped with a
cab. Keep the ground to mow free of foreign bodies.
Avoid mowing on stony or rocky grounds. If this is not
possible, take extra safety precautions, such as
- Fit polycarbonate screens inside the tractor cab's side
and rear windows, or install narrow mesh guards on
their exterior.
- Increase the cutting height to avoid contact with
stones or rocks.
Never start a mower conditioner when other people are
close.
Safety
13
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.
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.
Precautions for machine use
After each use, check the cutting tools (discs, knives)
and their attachment hardwa re in accordance with the
instructions given in the present manual. Immediately
replace any worn, damaged or missing cutting tool or
element. To do this, use the tool outfit supplied with the
machine. For your safety, only use genuine parts !
Regularly check the condition of the protection covers.
Immediatly replace any worn, damaged or missing
cover. Before engaging the PTO, rest the cutterbar on
the ground. Make sure all the guards are in place. Keep
all persons and animals away from the danger zone.
Stay a safe distance from the machine when the cutting
tools are in movement.
Never work in reverse.
After disengaging the PTO drive, cuttings tools can
continue rotating for some time. Stay away from the
machine until all moving parts have come to a complete
standstill.
If the machine hits an obstacle, disengage the PTO
drive, stop the tractor engine, remove the ignition key
and wait for all moving parts to come to a complete
standstill. Check the entire machine for any damage
before resuming work.
Mower conditioner
ALTERNA400
14
Safety
3. Location and description of safety decals on the machine
Location of safety decals
Mower conditioner
ALTERNA400
Safety
15
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 the tractor or 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.
Mower conditioner
ALTERNA400
Projections (3)
Stones and other debris pro jected by the moving parts
can travel a long distance. The protection covers must
always be in position and in good condition. Always sta y
at a safe distance from the machine.
Manoeuvring area (4)
Stay a safe distance from the machine. Crushing hazard.
16
Safety
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. For your own safety and for correct
machine operation, only use original manufacturer parts.
Mower conditioner
ALTERNA400
Safety
17
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.
Whatever the speed, we recommend, for everyones'
safety, not to exceed a maximum speed of 25 km/h.
The rear safety device comprises:
- 2 signalling lights (1)
(red light / stop light / turn signal light).
- 2 red reflectors (2).
- A signalling panel (3).
- A speed limit decal 4 supplied according to the
country where the machine is bound for.
Mower conditioner
ALTERNA400
The side device comprises:
• 4 amber reflectors (1).
• 4 amber reflectors (1)
18
Safety
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).
Mower conditioner
ALTERNA400
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.
Specific requirements for Germany
Speed
Always keep to the legal speed limit of 40 km/h for
driving a tractor-machine assembly on public roads.
Safety
19
$Machine specifications
1. Description and glossary
0
Mower conditioner
ALTERNA400
0
1 : Drawbar 2 : Check chains
3 : Parking stand 4 : Wheel chocks
5 : Cutterbars 6 : Side guards
7 : Front guards 8 : Drawbar shift cylinder
9 : Primary PTO shaft 10 : Handbrake
20
Machine specifications
Mower conditioner
ALTERNA400
0
0
1 : Transport wheels 2 : Work wheels
3 : Secondary PTO shaft 4 : Toolbox
5 : Swath shields
Machine specifications
21
Mower conditioner
2. Technical specifications
Attachment type 2 point linkage category 2 and 3
Number of discs 10
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’’)
ALTERNA400
Height in transport position 2.04 m (6’8’’)
Length in transport position 8.40 m (27’7’’)
Disc rotational speed 2610 min
Rotor speed 1000 min
-1
-1
Rotor width 1.75 m (5’9’’)
PTO speed 1000 min
-1
Weight 3500 kg (7716 lb) (approximately)
Minimum PTO power requirement 65 kW (90 hp)
Tyres (Transport wheels)
Tyres (Work wheels)
275/65 R18 Profil XP 27
2 x 400/60 - 15.5 14 PLY
22
Machine specifications
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