KUHN GMD800GII-FF Operator's Manual
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KUHN GMD800GII-FF Operator's Manual

KUHN GMD800GII-FF Operator's Manual

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OPERATOR'S MANUAL
KN198KGB D
Disc mower
KN198KGB D
- English - 04-2010

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Summary of Contents for KUHN GMD800GII-FF

  • Page 1 OPERATOR'S MANUAL KN198KGB D Disc mower KN198KGB D - English - 04-2010...

  • Page 3: Dear Owner

    GMD800GII-FF $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.

  • Page 4: Table Of Contents

    Disc mower GMD800GII-FF $Contents Dear Owner ........................1 Contents .........................2 Identification of the machine..................4 Front view............................4 Rear 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 ............17 Road safety equipment and recommendations................22...
  • Page 5 Disc mower GMD800GII-FF Instructions for work ....................37 Putting the machine into work position ..................37 Adjustments in working position....................39 Machine use............................ 41 Optional equipment ..................... 45 Raised skid shoes .......................... 45 Side deflector..........................45 Side deflector with high cone disk ....................46 Lighting and signalling ........................

  • Page 6: Identification Of The Machine

    Disc mower GMD800GII-FF $Identification of the machine 1. Front view 2. Rear view Identification of the machine...

  • Page 7: Model Identification Plate

    Disc mower GMD800GII-FF 3. 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. GMD800GII Type: Serial no.: 4. Optional equipment Tick box corresponding to the equipment fitted on your machine: Kit no.

  • Page 8: Safety

    Disc mower GMD800GII-FF $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 Disc mower GMD800GII-FF 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.).
  • Page 11 Disc mower GMD800GII-FF 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 Disc mower GMD800GII-FF For machines with hoppers or tanks: - If the total unit weight exceeds the tractor Gross Combined Weight Rating in accordance with the countrie's legislation, empty the hopper to travel on public roads. - In any case, we recommend to travel on public roads with empty hoppers and tanks.
  • Page 13 Disc mower GMD800GII-FF Stage 2: - Couple the machine to the tractor. To measure: - Load on front axle (t1): • Tractor + machine (transport position). To do: - If the front axle load (t1) is below 20% of the tractor tare (T), add ballast weights (M1) to exceed the minimum load on the front axle.
  • Page 14 Disc mower GMD800GII-FF Stage 4: To measure: - Load on rear axle (t2): • Tractor + machine (transport position). • Ballast weights. Checking: - Check in the tractor's operator's manual that the value measured is below the maximum allowed tractor rear axle load.
  • Page 15 Disc mower GMD800GII-FF Maximum speed Always keep to the legal speed limit for driving a tractor- machine assembly on public roads. 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.
  • Page 16 Disc mower GMD800GII-FF 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 17 Disc mower GMD800GII-FF 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 18 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 19: Location And Description Of Safety Decals On The Machine

    Disc mower GMD800GII-FF 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.
  • Page 20 Disc mower GMD800GII-FF Safety...
  • Page 21 Disc mower GMD800GII-FF 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...
  • Page 22 Disc mower GMD800GII-FF Crushing area (4) Never operate in an area where there is a crushing risk before all moving parts have come to a complete stop. Manoeuvring area (5) Stay a safe distance from the machine. Crushing hazard. Rotating cutting tools (6)
  • Page 23 Disc mower GMD800GII-FF Do not step on the machine (8) Do not step on the machine : Risk of falling or damaging the protection device. Prior to uncoupling the machine (9) - Place the cutterbar in horizontal position. - Lower parking lock.

  • Page 24: Road Safety Equipment And Recommendations

    GMD800GII-FF 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. The device is composed of: - 1 red reflector (1). Always keep to the legal speed limit for driving a tractor- machine assembly on public roads.

  • Page 25: Machine Specifications

    Disc mower GMD800GII-FF $Machine specifications 1. Description and glossary Cutterbar Parking lock Front guard Check chain Release cord Hitch pin Gearbox Lift cylinder Compensating spring 10 : Upper coupling yoke 11 : Safety breakback Machine specifications...

  • Page 26: Technical Specifications

    Disc mower GMD800GII-FF 2. Technical specifications Attachment type 3 point, Category 2 Number of discs Working width 3.10 m (10’2’’) Width in working position 4.98 m (16’4’’) Height in working position 1.17 m (3’98’’) Length in working position 1.33 m (4’41’’) Width in transport position 1.635 m (5’4’’)

  • Page 27: Putting Into Service

    Disc mower GMD800GII-FF $Putting into service 1. Description of control elements The machine is fitted with a release cord operated from the tractor cab. The machine is supplied with an 18 mm box wrench (1) to carry out certain adjustment and maintenance tasks.

  • Page 28: Coupling And Uncoupling

    Disc mower GMD800GII-FF 2. Coupling and uncoupling The machine adapts to tractors fitted with a 3 point linkage category 2. Description of coupling elements - A PTO shaft 1 3/8’’ - 6 splines. - A check chain. - A release cord.
  • Page 29 Disc mower GMD800GII-FF Hitch pin parallelism Adjust tractor lift rods so that hitch pins are parallel to the ground. Lateral adjustment of the lower links - Balance the play on either sides of the lift linkage and lock lower link stabilizers.
  • Page 30 Disc mower GMD800GII-FF Preparing the machine Positioning of lower links - Measure dimension E. - Adjust tractor lower link stabilizers to measure E = 50 mm (2"). Linkage adjustment - Measure dimension A. If measure A is below 2.10 m (6’11’’):...
  • Page 31 Disc mower GMD800GII-FF If measure A is comprised between 2.10 m (6’11") and 2.25 m (7’04"): - Place lower links in position b: Adjust machine lower hitch pin position: - Loosen the 8 screws (3). - Centre hitch pin (1) with regards to the mounting plate.
  • Page 32 Disc mower GMD800GII-FF Coupling the machine - Lower the tractor three-point linkage. - Position ball joints of tractor lower links in line with machine lower yokes. - Attach the lower links to the hitch pins. - Secure each hitch pin with lynch pin.
  • Page 33 Disc mower GMD800GII-FF Hydraulic connections Connect hydraulic hose (1) of the transport/work cylinder to a single acting valve with float position. Fit check chain See chapter:’’Frame height and check chains’’. Putting into service...
  • Page 34 Disc mower GMD800GII-FF Primary PTO shaft Make sure that the PTO shaft is correctly adjusted, to avoid premature wear and tear. The tractor PTO stub must rotate at a speed of 540 min Separate the two half PTO shafts and connect them to the machine's input shaft and to the tractor PTO stub.
  • Page 35 Disc mower GMD800GII-FF On machine side, attach guard chain to the main frame. Immediately replace any worn or damaged guard. Adjusting the machine Frame height and check chains. - Tractor fitted with a hydraulic position control function: • Lower tractor lift linkage in order to engage lift stop (1) in its housing.
  • Page 36 Disc mower GMD800GII-FF Uncoupling the machine For tractors not fitted with a hydraulic position control function, unhook and attach check chain to its support. - Place the cutterbar in horizontal position. - Release parking lock (1). - Engage parking latch behind the bevel gearbox mounting plate (2).

  • Page 37: Instructions For Transport

    Disc mower GMD800GII-FF $Instructions for transport Before placing the machine into transport position: Wait until the rotating parts have come to a complete stop. Check that nobody is located in the machine pivoting area. If there is someone, make sure the person moves away.

  • Page 38: Conformity With The Road Regulations

    Disc mower GMD800GII-FF The machine is in transport position. Never engage the tractor PTO drive when the machine is in transport position. 2. Conformity with the road regulations Before driving the machine on public roads, ensure that the machine complies with current highway code regulations.

  • Page 39: Instructions For Work

    Disc mower GMD800GII-FF $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...
  • Page 40 Disc mower GMD800GII-FF - Shift the mowing unit lift cylinder directional control valve in float position. - Lower the tractor lift linkage in working position. The machine is in working position. During work, only use the mowing unit lift cylinder to place the machine in headland turn position.

  • Page 41: Adjustments In Working Position

    Disc mower GMD800GII-FF 2. Adjustments in working position Before leaving tractor before adjusting, maintaining repairing 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 42 Disc mower GMD800GII-FF Swathing system The swathing system comprises: - 1 outer swath wheel (Adjustable). Position the swath wheel in order to obtain an angle between 16° (A) and 32° (A’). Check that there is a minimum clearance (J) of 15 mm (0.59’’) between the cone rib and the swath wheel.

  • Page 43: Machine Use

    Disc mower GMD800GII-FF Compensating spring tension The mowing unit is suspensed by means of compensating spring (1). In difficult working conditions, the compensating spring adjustment can be modified. - Place the machine in working position. - Lift mowing unit to release tension on the spring.
  • Page 44 Disc mower GMD800GII-FF Groundspeed Adapt the forward speed to the working conditions. Headland turn maneuvers Operate the cutterbar using the "pivot into transport/work" position cylinder. - Activate the transport/work cylinder control valve in the "pivot into transport" position. The cylinder lock (1) bottoms.
  • Page 45 Disc mower GMD800GII-FF Machine safety When hitting an obstacle: Before carrying out any maintenance or repairs on the machine, switch off the tractor engine, remove ignition key, wait until all moving parts have come to a standstill and apply park brake.
  • Page 46 Disc mower GMD800GII-FF If the break-away latch releases too easily after reset, tighten nut (1) to increase spring washer compression slightly. Respect spring washer layout. Basic adjustment: L= 95 mm (3.7’’) For normal functioning of the break-away latch, measure L must never be below 91 mm (3.60").

  • Page 47: Optional Equipment

    Disc mower GMD800GII-FF $Optional equipment 1. Raised skid shoes Kit no. 1036230 The raised skid shoes enable mowing higher, between 35 and 90 mm (1.4’’ - 3.5’’). Replace the end disc skids by the 2 raised skid shoes. raised skid...

  • Page 48: Side Deflector With High Cone Disk

    Disc mower GMD800GII-FF 3. Side deflector with high cone disk Kit no. 1036290 Large cone discs allow mowing dense or down crops with long stems. The side deflector prevents crop from wrapping around the outer large cone disk when mowing in dense or down crops with long stems.

  • Page 49: Lateral Signalling Equipment

    Disc mower GMD800GII-FF Instructions for transport - Position rear signalling device. - Connect signalling device wiring harness. Instructions for work - Disconnect signalling device wiring harness. - Position rear signalling device. 5. Lateral signalling equipment Kit no. 1016440 The machine can be fitted with specific signalling lights to comply with the road regulations.

  • Page 50: 1000 Min-1 Drive Kit

    Disc mower GMD800GII-FF 1 on each machine side. 1 in combination with signalling panel. Lighting and signalling: Kit no. 1026100 6. 1000 min drive kit Kit no. 1066010 Belt and pulley assembly for tractors with a pto speed of 1000 min...

  • Page 51: Longer Hitch Pins

    Disc mower GMD800GII-FF 7. Longer hitch pins Kit no. 56820700 The longer hitch pin enables offsetting the machine by 200 mm (7.9’’). Linkage adjustment - Measure dimension A. If measure A exceeds 2.40 m (7’10"): Position lower links. Adjust machine lower hitch pin position: - Loosen the 8 screws (3).

  • Page 52: Maintenance And Storage

    Disc mower GMD800GII-FF $Maintenance and storage Before carrying out any maintenance or repairs on the machine, switch off the tractor engine, remove ignition key, wait until all moving parts have come to a standstill and apply park brake. 1. Frequency chart Maintenance intervals are indicated for normal conditions of use.

  • Page 53: Lubrication

    Disc mower GMD800GII-FF 2. Lubrication Lubricate with SHELL multi-purpose grease grade NLGI 2. PTO shaft Primary PTO shaft - Every 8 hours: • universal joints (1). - Every 20 hours: • transmission tube (2). - Every 40 hours: • guide rings (3).
  • Page 54 Disc mower GMD800GII-FF Cutterbar draining and refilling. Before draining oil, operate the machine for a few minutes so that the oil warms up. The cutterbar is lubricated with 2.25 L (0.59 US gal) of SHELL SPIRAX A extreme-pressure gear oil with viscosity grade SAE 80W90 and API grade GL5.
  • Page 55 Disc mower GMD800GII-FF Changing angle gearbox oil. Before draining oil, operate the machine for a few minutes so that the oil warms up. The angle gearbox is lubricated with 0.45 L (0.12 US gal) of SHELL SPIRAX A extreme-pressure oil for mechanical transmissions with viscosity grade SAE 80W90 and API grade GL5.

  • Page 56: Maintenance

    Disc mower GMD800GII-FF 3. Maintenance Before carrying out any maintenance or repairs on the machine, switch off the tractor engine, remove ignition key, wait until all moving parts have come to a standstill and apply park brake. Belt tension Regularly check belt tension and in particular during the first hours of use.
  • Page 57 Disc mower GMD800GII-FF Checking cutterbar oil level Regularly check the cutterbar oil level: • Place cutter bar in vertical position. • Remove filler plug (1) and its washer. • Check the oil level. • Top up if necessary. • Clean...
  • Page 58 Disc mower GMD800GII-FF Check angle gearbox oil level Regularly check the oil level: • Place the cutterbar in horizontal position. • Remove drain plug (1) and its washer. • Check the oil level. • Top up if necessary. • Clean and reinstall drain plug (1) and its washer.
  • Page 59 GMD800GII-FF Inspection of knives and securing elements Immediately replace worn or damaged parts with genuine KUHN parts. The following procedures take into account the 2 machine configuration possibilities: I ) For machines up to serial number K0211 Coupling device (a).
  • Page 60 Disc mower GMD800GII-FF I ) For machines up to serial number K0211 Coupling device (a). Knives Inspect systematically all knives before the machine is operated to: - guarantee the cutting quality. - guarantee safety in use. - Prevent cutterbar damage risks.
  • Page 61 Disc mower GMD800GII-FF 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 (2): - When there is visible distortion.
  • Page 62 Disc mower GMD800GII-FF Replace nuts in the following cases (1): - When nut wear reaches a = 5 mm (0.2’’). Check the condition of the fixing elements regularly and also the torque of the knife-fixing bolt: - Torque: 12 daN m (89 lbf ft).
  • Page 63 Disc mower GMD800GII-FF Parking - Clean the top side of the disk guard. - Clean cavities between disc and spring plate. - Fully insert special tool between disc and spring plate. - Pivot special tool downwards to free spring plate from screw head.
  • Page 64 Disc mower GMD800GII-FF Fitting Knives can be turned over on the same disc to use the other cutting edge or replaced. On each knife, an arrow indicates the disc's direction of rotation. Knife for disk rotating to the left: Part no.
  • Page 65 Disc mower GMD800GII-FF - Check that screw head (2) is free to slide in spring plate hole (3). - Remove special tool. - Rotate disk by half a turn. - Repeat previous tasks. - Repeat previous tasks on the other disks.
  • Page 66 GMD800GII-FF Disc replacement Inner disc: The replacement of the inner disk must be carried out by your Kuhn authorized dealer. Intermediate disc: - Place a wooden wedge (2) between two discs to stop them from moving. - Remove 2 bolts (1) and their spring washers using the box spanner supplied with the machine.
  • Page 67 Disc mower GMD800GII-FF Spring plate replacement The inner disk spring plate: The replacement of the inner disc spring plate must be carried out by a Kuhn authorized dealer. Intermediate disk spring plate: - Remove the disc. • See section: ’’Disc replacement’’.
  • Page 68 Disc mower GMD800GII-FF II ) For machines up to serial number K0211 Coupling device (b) or For machines with serial number as from K0212. Knives Inspect systematically all knives before the machine is operated to: - guarantee the cutting quality.
  • Page 69 Disc mower GMD800GII-FF Fixing elements Check the fixing elements: - After hitting an obstacle. - When replacing knives. - At the start of each season. The fixing bolts should be changed in the following cases (2): - When there is visible distortion.
  • Page 70 Disc mower GMD800GII-FF Replace nuts in the following cases (1): - When nut wear reaches a = 5 mm (0.2’’). Check the condition of the fixing elements regularly and also the torque of the knife-fixing bolt: - Torque: 12 daN m (89 lbf ft).
  • Page 71 Disc mower GMD800GII-FF Parking - Clean the top side of the disk guard. - Clean cavities between disc and spring plate. - Fully insert special tool between disc and spring plate. - Pivot special tool downwards to free spring plate from screw head.
  • Page 72 Disc mower GMD800GII-FF Fitting Knife for disk rotating to the left: - Part no. K6802970 Knife for disk rotating to the right: - Part no. K6802980 - Pivot special tool downwards to free spring plate from screw head. - Insert the new knife on the screw head.
  • Page 73 Disc mower GMD800GII-FF - Check that screw head (2) is free to slide in spring plate hole (3). - Remove special tool. - Rotate disk by half a turn. - Repeat previous tasks. - Repeat previous tasks on the other disks.
  • Page 74 GMD800GII-FF Disc replacement Inner disc: The replacement of the inner disk must be carried out by your Kuhn authorized dealer. Intermediate disc: - Place a wooden wedge (2) between two discs to stop them from moving. - Remove 2 bolts (1) and their spring washers using the box spanner supplied with the machine.
  • Page 75 Disc mower GMD800GII-FF Spring plate replacement The inner disk spring plate: The replacement of the inner disc spring plate must be carried out by a Kuhn authorized dealer. Intermediate disk spring plate: - Remove the disc: • See section: ’’Disc replacement’’.

  • Page 76: Storage

    Disc mower GMD800GII-FF 4. Storage At the end of each season - Clean the machine thoroughly. - Drain gearbox and cutterbar and refill with new oil. - Touch up any areas of damaged paintwork. - Store machine with the cutter bar in horizontal position in a sheltered dry place.

  • Page 77: Trouble Shooting Guide

    Disc mower GMD800GII-FF $Trouble shooting guide Problem Cause Remedy Dull or broken knives. Replace knives. Make sure the arrow on the Knives not installed correctly. knife upper face is pointing in Uneven stubble. the disc's direction of rotation. Insufficient disk speed.
  • Page 78 Disc mower GMD800GII-FF Incorrect mowing unit The tractor valve double acting Use the tractor double acting positioning with regards to the position has not been used to position to lower the mowing tractor when placed in working lower the mowing unit.

  • Page 79: Appendix

    Disc mower GMD800GII-FF $Appendix 1. Calculating the load on an axle When coupling a tool to the front and rear 3-point lift linkage, the maximum authorized payload must not be exceeded. The load on the tractor front axle must always represent 20 % of the tractor unladen weight.
  • Page 80 Disc mower GMD800GII-FF Rear tool or front-rear combination: 1) Calculation of the minimum front ballast weight M1 minimum M2 x (c+d) - T1 x b + 0.2 x T x b minimum Write the minimal additional weight in the chart.
  • Page 81 Disc mower GMD800GII-FF Table: Actual value obtained Value authorized Double value of the by calculation according to authorized capacity operator's manual per tyre (2 tyres) Minimum front/rear ballasting kg ≤ Total weight kg ≤ kg ≤ Load on front axle kg ≤...
  • Page 82 Disc mower GMD800GII-FF Determining the machine weight (M2) and the position of its centre of gravity (d) If the data required to calculate the total weight, axle loads and minimum ballasting are not supplied, use the following method. Tractor only: - T1: Load on front axle.
  • Page 83 Disc mower GMD800GII-FF - T: Axle loads. • Tractor only. Appendix...
  • Page 84 Disc mower GMD800GII-FF Rear tool or front-rear combination: If the total unit weight exceeds the tractor Gross Combined Weight Rating in accordance with the countrie's legislation, empty the hopper to travel on public roads. In any case, we recommend to travel on public roads with empty hoppers and tanks.

  • Page 85: Limited Warranty

    Disc mower GMD800GII-FF $Limited warranty Limited warranty...
  • Page 86 Disc mower GMD800GII-FF Limited warranty...

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