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KUHN ALTERNA 500R, Assembly & Operators Manual

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KUHN ALTERNA 500R Assembly & Operators Manual Download Page 3

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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

Securing discs and knives

27

Inspection of knives & securing elements

28 - 29

Important recommendations

30

Lubrication

31 - 36

Optional equipment

36

Storing the mower conditioner

37

Trouble Shooting Guide

38 - 39

Hydraulic schematic

40

Electric lay out, connections and schematic

41

Seven-conductor electrical connector (for North America)

42

Limited warranty

43 - 44

Copyright 2002 KUHN S.A.

Summary of Contents for ALTERNA 500R

Page 1: ...ASSEMBLY OPERATORS MANUAL MOWER CONDITIONERS ALTERNA 400 400 R 500 500 R No 95105 D GB 01 2002 ...

Page 2: ...l instruct you on the general operation of your machine He is interested 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 ass...

Page 3: ...nsport position 17 18 Adjustments 19 25 Securing discs and knives 27 Inspection of knives securing elements 28 29 Importantrecommendations 30 Lubrication 31 36 Optionalequipment 36 Storing the mower conditioner 37 TroubleShootingGuide 38 39 Hydraulic schematic 40 Electric lay out connections and schematic 41 Seven conductorelectricalconnector forNorthAmerica 42 Limitedwarranty 43 44 Copyright 2002...

Page 4: ...n is at the risk and responsibility of the operator Designated use of the machine also means following operation maintenance and repair recommendations given by the manufacturer using only genuine spare parts equipment and accessories as designated by the manufacturer TheALTERNAmowerconditionersmustonlybeoperated maintainedandrepairedbycompetentpersonswhoare familiar with machine specifications an...

Page 5: ...nd in accordance with current safety standards 9 When attaching or removing the machine place the parking stand into the corresponding position 10 Special care should be taken when attaching or removing the machine from the tractor 11 Before attaching the machine make sure that the maximum permitted front axle weight and gross weight of the combination are not exceeded 12 Do not surpass the maximu...

Page 6: ...t off accidentally causing accident or damage 4 Before operating the machine check the tightness of all nuts and bolts particularly on rotating parts blades tines knives spades 5 Before operating the machine ensure that all safety guards are firmly in place and in good condition If worn or damaged replace immediately ATTACHMENT 1 When attaching or removing the machine from the tractor make sure th...

Page 7: ...ever engage PTO shaft when tractor motor is turned off 11 Never surpass PTO angle recommended by the manufacturer 12 WARNING Rotating elements can continue turning momentarily after PTO is disengaged Keep clear until 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 gu...

Page 8: ... 8 Before any adjustments maintenance or repairs are carried out lower the machine 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 mach...

Page 9: ...roperly 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 P...

Page 10: ...ED ON YOUR MACHINE IN THE AREAS INDICATED THEY ARE INTENDED FOR YOUR PERSONAL SAFETY AND FOR THE SAFETY OF THE PEOPLE WORKING WITH YOU THE TEXT SHOWN ON THEM GIVES THEIR PRECISE MEANING ENSURE THAT THESE PICTORIALS ARE ALWAYS LEGIBLE IF THEY ARE NOT REPLACE THEM ...

Page 11: ... 9 4 5 8 9 6 7 3 1 2 ...

Page 12: ...A 400 single wheels 1 8 bar 29 psi ALTERNA 500 500 R ALTERNA 400 400 R Attachment 2 point on Gyrodine hitch pivoting lower links Working width 4 85 m 16 3 90 m 13 Transport width 2 5 m 8 2 Number of discs 10 8 Number of blades per disc 2 P T O speed rotational frequency 1000 rpm min 1 Finger rotor speed rotational frequency 1000 rpm min 1 Ribbed roller speed rotational frequency 910 rpm min 1 Aver...

Page 13: ...port 3 off the ground by activating the tractor hydraulics Remove pin 6 and lock parking stand 7 into its vertical position using handle 8 Lower the tractor draught arms so that the weight of the drawbar is supported by parking stand 7 Remove the two pins 5 and take off the drawbar support 3 3 For reduced bulk the left rear light support ele ment has not been installed in its final position Remove...

Page 14: ...ing check chainsorlinkagestabilizerbarsprovidedatthesame time making sure that the tractor PTO and machine input shaft are lined up in the vertical plane Fitting the primary PTO shaft ConnecttheprimaryPTOshaft sflangedyoke 8 tothe Gyrodine slip clutch Secure in place using 6 self locking bolts 9 M 12 x 25 Tighten to a torque of 9 daNm 66 ft lbs Make sure bolts are torqued to 9 daNm 66 ft lbs To av...

Page 15: ...own in the opposite drawing For your safety there must be a minimum tube overlap of 180 mm 7 when the PTO shaft is in its maximum extended position Make sure the PTO shaft is con nected to the 1000 min 1 tractor PTO 3 All machine operations are controlled by the tractor s two double acting directional valves a Connect hydraulic hoses 1 to the outlets of the first directional valve which will be re...

Page 16: ...re relieved of the drawbar s weight Blockthewheelswithwedgesiftheareaisnoteven and level Uncouple the tractor draught arms the check chains and the PTO shaft Safety chain 3 supports the primary PTO shaft when the machine is disconnected from the tractor In this position the PTO shaft is not in contact with the ground thus avoiding deterioration due to dust and dirt Holder 4 provides effective prot...

Page 17: ...eck that the tractor lower links are completely raised When operating on sloping ter rain and to avoid that the ma chine goes off course activate DE1 to extend the cylinders for the work wheels so that they stay as near to the ground as possible 1 Activate DE2 until machine and drawbar are at a 90 angle to each other 2 Activate DE1 to fully extend the cylinders for the work wheels 3 Press thumb sw...

Page 18: ...a distance of 700 mm 2 4 from the ground Hook one end of the check chains R to the hitch brackets C by means of the shackles S and attach the other side to the tractor s top link yoke by means of the top link hitch pin A Lower the 3 point lift The attachment is correct when the underside face I of the tongue is approximately horizontal and the lower hitch pins are at a distance H of around 650 mm ...

Page 19: ...s are fully extended keep the valve shifted for a few seconds after the front transport wheel has closed up against its stop Then return DE2 to neutral 4 Shift DE1 in the opposite direction to lower the unit onto the transport wheels When operating on sloping ter rain and to avoid that the ma chine goes off course keep the work wheels as near to the ground as possible WORK TO TRANSPORT POSITION Wh...

Page 20: ...se the swathboards completely in order to reduce the machine s transport width Before transporting the machine ensure that a The cutting conditioning unit is correctly locked under the drawbar b Work wheels are fully raised cylinder rods com pletely retracted c The 4 hydraulic hoses are unplugged and the quick couplers are housed in their support d The electric terminal is unplugged so that the tr...

Page 21: ... 5 ft lbs for ALTERNA 400 400 R to be transmitted This setting is applicable to average operating conditions Check if this setting is suitable for the given condi tions during the first few hours of use If the spring pressure is too light plates slip continuously or intermittently at frequent intervals resulting in overheating and rapid wear of the friction plates Over pressured or completely coil...

Page 22: ...t the cylinder 1 must then be extended to an intermediary position which is defined by the end position sensor 2 P N 832 300 04 The sensor is activated by the core 3 of the sliding rod 4 when the measure A 557 mm 1 10 is reached NOTE The measure A 557 mm 1 10 is preinstalled at factory 4 Drawbar pressure pad adjustment The preload applied by pushers 5 onto pressure pad 6 is adjusted as follows Rot...

Page 23: ...crew in bolt 2 as far as it will go Press thumb switch and at the same time operate DE2 to lower the transport wheels Undo bolt 2 until its head operates the sensor 1 which in turn extinguishes the blue indicator lamp built into the junction box Undo bolt 2 one more turn and retighten lock nut 3 while at the same time keeping bolt 2 from rotating Ensure that a minimum safety clearence of 1 mm isma...

Page 24: ...ecorrespondinghole Secureinplacewithbolt 5 7 Cutterbar and conditioning unit ground pressure When the machine is in the working position either on the left or right side of the tractor the underside of the drawbar is horizontal most of the cutterbar s weight is carried by a set of springs The ground pressure should be adjusted in such a way that the left or right side of the platform can be raised...

Page 25: ...s conditioning intensity Do not forget to close hoods 2 after having manipulated handles 1 Other than these five positions which govern conditioning intensity the comb has the advantage of being reversible and has two different conditioning surfaces one for natural grasses and one for more delicate crops Disassembling and reversing comb Remove bolts 3 connecting lever 1 1a and pin 4 to the comb Pu...

Page 26: ...ty Rotating nut 3 anti clockwise decreases conditioning intensity From the factory roller pressure is set at approximately 2 5 kg cm 14 lbs inch Clearance is set between 2 and 3 mm A minimum clearance of 2 mm must always be maintained Checktherollclearanceandparallelismoccasionally Incorrect adjustment generates vibrations which can create damage Lateral stop screws 4 are used to adjust the parall...

Page 27: ...he link 3 on the gearbox with screw 4 and washer 5 4 Locktherollersusingwoodenwedges 6 bycentringtheupperrollinthelowerroll withequaldistancebetween the lugs and grooves of the opposite roll 5 Thoroughly degrease the contact area between mounting surfaces of pulley 7 and pinion 8 using a grease eliminator such as Loctite 7063 6 Apply a Loctite 638 retaining product on these mounting surfaces 7 Ins...

Page 28: ...mid distance between the pulleys Belts must not be changed individu ally Only replace belts as a complete set Loosen the belts when not using the machine for long periods 10 mm MAXI 12 Swath width Twoadjustableswathboardsenabletheusertochange the swath width according to the crop density and the weather conditions Loosen the screws 4 ALTERNA 400 400 R or the handles 5 ALTERNA 500 500 R open or clo...

Page 29: ...ves fitted to anincorrectdisccauseruggedcutting Worn knives should either be turned over to use the other cutting edge on the same disc or replaced Knives bolts and nuts are made of a special steel Never use replacement parts other than genuine KUHN spare parts Discs a To avoid interference between blades and discs scrupulously respect the disc positioning shown in the figure below b Discs are sec...

Page 30: ...utting quality risk of damage to the cutterbar 2 Worn knives Length A of a knife should be greater than 65 mm The width B of a knife measured at a distance of 10 mm away from the edge of the disc should be greater than 34 mm The hole L for the securing bolt must not become oval by more than 20 mm for an 18 mm hole B SECURING ELEMENTS To be inspected regularly particularly the tightening torque of ...

Page 31: ...ecome inoperational due to inclusion of water oil or dirt When wear on the head reaches the contact area of the knife When the diameter D of the bolt shoulder is less than 15 mm 5 8 2 The nuts must be replaced When the contact washer has lost its elasticity or when it becomes loose from the nut When wear on the nut reaches a 5 mm For the correct operation of your machine always use genuine KUHN sp...

Page 32: ...uency of the discs will be considerably re duced when cutting It is worthwhile to work with sharp knives Adjusting the suspension system to lighten the cutting conditioning unit s weight on the ground allows the skids to glide over the ground without damaging the grass stubble It is important to retighten all bolts and nuts after the first 2 3 hours of use 3 Secondary PTO shaft Retighten the conic...

Page 33: ...he platform place a 300 mm 12 high wedge under one end skid and a 150 6 high wedge under the other end skid then lower the platform onto the wedges Remove end plate 1 from the lower end of the cutterbar and collect oil in a catchment tank of at least 3 1 2 pint capacity Allow oil to drain completely Wait for dripping to stop Reinstall end plate 1 and the gasket Tighten the three allen screws to 9 ...

Page 34: ...ubt as to the amount of oil contained in the cutterbar do not add oil Drain the oil completely and refill with the prescribed quantity II Central gearbox Check oil level and refill if necessary using dipstick plug 1 Oil is drained by means of plug hole 2 in the bottom of the gearcase The gearbox is filled with 5 75 liters of SHELL SPIRAX SAE 80 W EP GL4 oil Imperatively change oil after the first ...

Page 35: ...vot gearbox The upper central pivot gearbox 5 is fitted with 1 75 liters of SHELL SPIRAX EP 80 oil Check oil level and refill if necessary using plug 7 which has a dipstick 6 with an inlaid mark indicating oil level Drain oil by drawing it up through hole 7 using a syringe Note The upper central pivot gearbox has been equipped with this dipstick as from the 1999 production year V Lower central piv...

Page 36: ...ase Fittings There are 20 grease fitting on the ALTERNA mower conditioner as shown on the following photos Some guards have been removed for clearer illustration Grease all points every 8 hours of work with Shell Multi PurposegreaseNLGIgrade2 All grease fittings are identified by the decal opposite For safety reasons grease points 4 and 5 with work wheel cylinders retracted ...

Page 37: ... 35 LUBRICATION ...

Page 38: ...ugh hole 17 provided in the guard tubes without removing the PTO shaft OPTIONAL EQUIPMENT 1 PTO SHAFT YOKES 1 3 8 6 splines Kit no 4503 710 1 3 4 6 splines Kit no 4503 712 1 3 4 20 splines Kit no 4503 713 2 Rigidified blades Ref 564 516 00 x 16 ALTERNA 400 Ref 564 516 00 x 20 ALTERNA 500 Rigidified blades may be recommended for mowing in difficult conditions 3 Wide spreading equipment for ALTERNA ...

Page 39: ...tracted ie 1 central pivot cylinder 2 transport wheel cylinders 7 Slacken the V belts and check their condition II AT THE BEGINNING OF THE SEASON 1 Attach the machine to the tractor and place it on level ground in the working position 2 Check all oil levels and grease the machine as described in the lubrication section 3 Retension the V belts see adjustments section Make sure all guards are firmly...

Page 40: ...d incorrectly Damaged or broken knives Excessive forward speed Flotation of cutterbar conditioning unit poorly adjusted Skids incorrectly adjusted Working in very wet conditions Excessive ground pressure Conditioning combs incorrectly positioned Conditioning rollers are no longer parallel Insufficient PTO speed rotational frequency PROBLEM Poor cutting quality Stubble too high Soil accumulates in ...

Page 41: ... Bring PTO speed rotational frequency up to 1000 rpm min 1 and set it with the hand throttle Adapt tractor speed to condition of crop and density Adapt comb adjustment to condition of crop Correct the swathboard position Clean and or replace elements see hydraulic schematic POSSIBLE CAUSE Unbalanced conditioning rotors Conditioning rollers are no longer correctly adjusted to be parallel Damaged co...

Page 42: ... body at the front of the drawbar houses 4 metal filter screens which should be removed and cleaned twice per season for trouble free function of the hydraulics Use a 38 mm wrench to remove the 4 ports which maintain the filter screens in place ...

Page 43: ... 41 ELECTRIC LAY OUT CONNECTIONS AND SCHEMATIC ...

Page 44: ...unction Terminal connection ISO 1724 plug SAE J 560b plug White Ground 3 1 Black Left running lights 7 6 Yellow Left turn hazard 1 3 Red Stop lights 6 4 Green Right turn hazard 4 5 Brown Right running lights 5 6 Blue Not used 2 7 Note that the black and brown wires must be connected together on SAE type connectors for proper light opération The red wire should only be attached to the 4 terminal if...

Page 45: ...idance on methods of testing Annex to AIC 1896 117 REV February 1988 Health and Safety Executive The method employed corresponds to the method No 4 in this document Unspecified testing conditions comply with ISO 5131 standard Measuring equipment conforms to NF S 31 009 standard The tractor used has a power of 170 kW A weighted emission sound pressure level L A eq inside tractor cab with closed win...

Page 46: ...f it has been misused neglected or damaged by accident or let out on hire Nor can claims be accepted if parts other than those manufactured by us have been incorporated in any of our equipment Furthermore the Company shall not be responsible for damage in transit or handling by any common carrier and under no circumstances within or without the warranty period will the Company be liable for damage...

Page 47: ...sions on all questions as to defect and to the exchange of any part or parts That all safety instructions in the Operator s Manual shall be followed and all safety guards regularly inspected and replaced where necessary No warranty is given on second hand products and none is to be implied Persons dealing in the Company s products are in no way legal agents of the Company and have no right or auth...

Page 48: ... N O T E S ...

Page 49: ......

Page 50: ......

Page 51: ...ctive The Operator should respect all Health and Safety regulations as well as the Highway Code For your own safety use only genuine KUHN spare parts The manufacturer disclaims all responsibilities due to incorrect use or non compliance with the recommendations given in this manual ...

Page 52: ...Fabriques F 67706 SAVERNE CEDEX FRANCE Tél 33 0 3 88 01 81 00 Fax 33 0 3 88 01 81 03 www kuhnsa com E mail info kuhnsa com Société Anonyme au Capital de 19 488 000 Euros For your safety and to get the best from your machine use only genuine KUHN parts ...

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