KUHN GMD802 Operator's Manual
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KUHN GMD802 Operator's Manual

KUHN GMD802 Operator's Manual

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OPERATOR'S MANUAL
KN082DGB D
Disc mower
- English - 03-2010
KN082DGB D

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  • Page 1 OPERATOR'S MANUAL KN082DGB D Disc mower - English - 03-2010 KN082DGB D...

  • Page 3: Dear Owner

    Designated use of the machine The GMD802 mower must only be used for the purpose for which it was manufactured: 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

    Disc mower GMD802 $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 ............15 Road safety equipment and recommendations................19...
  • Page 5 Disc mower GMD802 Instructions for work ....................38 Putting the machine into work position ..................38 Adjustments in working position....................39 Machine use............................ 46 Optional equipment ..................... 47 PTO shafts ............................47 Side deflector kit ..........................48 Large cone discs ..........................48 Maintenance and storage....................

  • Page 6: Identification Of The Machine

    Disc mower GMD802 $Identification of the machine 1. Front view 2. Rear view Identification of the machine...

  • Page 7: Model Identification Plate

    Disc mower GMD802 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. GMD802 Type: Serial no.: 4. Optional equipment Tick box corresponding to the equipment fitted on your machine: Part no.

  • Page 8: Safety

    Disc mower GMD802 $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 GMD802 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 GMD802 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: Hydraulic Circuit

    Disc mower GMD802 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 Disc mower GMD802 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: Safety Decals

    Disc mower GMD802 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 Disc mower GMD802 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.

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

    Disc mower GMD802 3. Location and description of safety decals on the machine Location of safety decals Safety...
  • Page 18 Disc mower GMD802 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 19 Disc mower GMD802 Manoeuvring area (5) Stay a safe distance from the machine. Crushing hazard. Rotating cutting tools (6) 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.
  • Page 20 Disc mower GMD802 Danger accumulator (9) The hydraulic accumulator contains gaz and oil under pressure. To park the machine or carry out maintenance work, conform with the instructions given in the operator's manual. Safety...

  • Page 21: Road Safety Equipment And Recommendations

    GMD802 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: - A signalling light (1). - A signalling panel (2).

  • Page 22: Machine Specifications

    Disc mower GMD802 $Machine specifications 1. Description and glossary Parking stand Check chain Hydraulic valves Gauges Connecting frame Hitch pins Cutterbar Central gearbox Compensation cylinder 10 : Hydro-pneumatic accumulators 11 : Side gearbox 12 : Front guard 13 : Work/transport cylinder...

  • Page 23: Technical Specifications

    Disc mower GMD802 2. Technical specifications Attachment type 3 point, Category 2 Number of discs Working width 3.11 m (10’2’’) Width in working position 5.28 m (17’4’’) Height in working position 1.40 m (4’7’’) Length in working position 1.34 m (4’4’’) Width in transport position 1.85 m (6’1’’)

  • Page 24: Sound Levels

    Disc mower GMD802 3. Required equipment Central gearbox 540 min Machines fitted with a 540 min central gearbox must be driven with a PTO stub rotating at 540 min Central gearbox 1000 min Machines fitted with a 1000 min central gearbox must be driven with a PTO stub rotating at 1000 min 4.

  • Page 25: Putting Into Service

    Disc mower GMD802 $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 26 Disc mower GMD802 Preparing the tractor Check that the tractor's authorized gross weight 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.

  • Page 27: Preparing The Machine

    Disc mower GMD802 Preparing the machine Linkage adjustment Measure dimension A. If measure A is below 2.10 m (6’11’’): Place lower links in position (a). Adjust machine lower hitch pin position: - Unscrew the 8 bolts (3). - Position hitch pin (1) at measure A = 10 mm (0.4’’).
  • Page 28 Disc mower GMD802 If measure A is comprised between 2.10 m and 2.30 m (6’11’’ - 7’7’’): Place lower links in position (b). Adjust machine lower hitch pin position: - Unscrew the 8 bolts (3). - Centre hitch pin (1) with regards to the mounting plate.
  • Page 29 Disc mower GMD802 If measure A exceeds 2.30 m (7’7’’): Place lower links in position (c). Adjust machine lower hitch pin position: - Unscrew the 8 bolts (3). - Position hitch pin (2) at measure A = 10 mm (0.4’’).
  • Page 30 Disc mower GMD802 Coupling the machine Lower the tractor three-point linkage. Adjust levelling rods to position draft arms as close as possible below hitch pins (A = 30-50 mm (1-2’’) maximum). Lift the tractor lift linkage to connect the draft arms to the hitch pins.
  • Page 31 Disc mower GMD802 Hydraulic connections The machine hydraulic suspension circuit is pressurized at the factory. Connect the 2 hydraulic hoses of the transport/work cylinder to a double acting valve (1). Connect the hydraulic hose to the single acting valve with float position (2).
  • Page 32 Disc mower GMD802 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 or 1000 min Separate the two half PTO shafts and connect them to the machine's input shaft and to the tractor PTO stub.
  • Page 33 Disc mower GMD802 On machine side, attach guard chain to the headstock hole. Immediately replace any worn or damaged guard. Secondary PTO shaft Before adjusting, maintaining or repairing the machine, turn off ignition key and wait until all moving parts have come to a complete stop.
  • Page 34 Disc mower GMD802 - Tighten nuts to release the friction discs. - Let the friction discs slip for a few seconds. - Thread nuts away until they bottom against the threaded studs. The friction slip clutch is ready to function.
  • Page 35 Disc mower GMD802 Hitch pin parallelism From the transport position: - Pull on cord to release latch. - Activate the transport/work cylinder control valve in the "pivot into work" position. - Activate the transport/work cylinder control valve in the "lift into headland turn" position.
  • Page 36 Disc mower GMD802 Frame height and check chains. - Tractor fitted with a hydraulic position control function: • Lower the tractor lift linkage so that hitch pins are at a distance H = 600 mm (2’) from the ground. • Note the corresponding lever position in the tractor cab.
  • Page 37 Disc mower GMD802 Uncoupling the machine For tractors not fitted with a hydraulic position control function, unhook and attach check chain to its support. - Place the machine in transport position. - Lower parking stand (1). - Secure parking stand using lock (2).

  • Page 38: Instructions For Transport

    Disc mower GMD802 $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 within the machine pivoting area. - If there is someone, make sure the person moves away.

  • Page 39: Conformity With The Road Regulations

    Disc mower GMD802 2. Conformity with the road regulations Before driving the machine on public roads, ensure that the machine complies with current highway code regulations. Check that the light boards are clean and that the lighting equipment functions before transporting the machine on public roads.

  • Page 40: Instructions For Work

    Disc mower GMD802 $Instructions for work Before placing the machine in working position: - Wait until the rotating parts have come to a complete stop. - Check that nobody is within the machine pivoting area. - If there is someone, make sure the person moves away.

  • Page 41: Adjustments In Working Position

    Disc mower GMD802 2. Adjustments in working position Cutting height The desired cutting height is obtained directly by adjusting the top link length. The height can be adjusted between 30 and 80 mm (1.1’’ - 3.1’’) depending on the tractors.
  • Page 42 Disc mower GMD802 Ground pressure The ground pressure adjustment determins the safety breakback adjustment: - Example: when the pressure in the gauges increases, mowing unit ground pressure decreases and the breakback force increases. The mowing unit suspension is obtained by 2 hydro-pneumatic accumulators.
  • Page 43 Disc mower GMD802 Pressure adjustment Increase pressure in the hydro-pneumatic accumulator: - Place the machine in working position. The following adjustments do not cause the machine to move. - Open the hydraulic valve using the 18 box spanner supplied with the machine. Position (a).
  • Page 44 Disc mower GMD802 Transport stabilizing pressure The mowing unit cushioning is obtained with an hydro-pneumatic accumulator. In modifying accumulator's pressure, the mowing unit's cushioning varies. To check the mowing unit's stabilizing pressure Place the machine in transport position. Check the pressure given on the gauge: - NORMAL operating pressure = 160 bar (2285 psi).
  • Page 45 Disc mower GMD802 Pressure adjustment Increase pressure in the hydro-pneumatic accumulator: - Place the machine in transport position. The following adjustments do not cause the machine to move. - Open the hydraulic valve using the 18 box spanner supplied with the machine. (Position (a)).
  • Page 46 Disc mower GMD802 Swathing system The swathing system comprises: - 2 Swath wheels. The swath width is 2.40 m (7’10") approximately. Right swath wheel Make sure that distance (J) equals at least 15 mm (0.6’’). The swath wheel's lateral position (A) and angle (X) can be adjusted.
  • Page 47 Disc mower GMD802 Left swath wheel Make sure that distance (J) equals at least 15 mm (0.6’’). The swath wheel's lateral position (A) and angle (X) can be adjusted. Instructions for work...

  • Page 48: Machine Use

    Disc mower GMD802 3. Machine use Before mowing and to reduce risks of projections, lower the front guard. Keep all persons and animals away from the machine danger zone. Never lean or step on the protection cover. Before the machine engages the crop:...

  • Page 49: Optional Equipment

    Disc mower GMD802 $Optional equipment 1. PTO shafts 1 3/8" - 6 spline pto shaft Kit no. 4600415 Equipment available for machines fitted with a 1 000 min central gearbox. 1 3/8’’ - 21 spline yoke Kit no. 4603256 A specific yoke is available as option for modifying pto shaft 4600415 for tractors equipped with a 1 3/8’’...

  • Page 50: Side Deflector Kit

    Disc mower GMD802 2. Side deflector kit Kit no. 1036330 The side deflectors are recommended for mowing dense or down crops with long stems. Fit the 2 side deflectors on the outer side plates of the cutterbar stiffener. 3. Large cone discs Kit no.

  • Page 51: Maintenance And Storage

    Disc mower GMD802 $Maintenance and storage Before adjusting, maintaining or repairing the machine, turn off ignition key and wait until all moving parts have come to a complete stop. 1. Frequency chart After the Every 200 first 10 Every 30...

  • Page 52: Lubrication

    Disc mower GMD802 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 53 Disc mower GMD802 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 54 Disc mower GMD802 Lateral gearbox draining Before draining oil, operate the machine for a few minutes so that the oil warms up. The angle gearbox is lubricated with 0.9 L (0.23 US gal) of SHELL SPIRAX A extreme-pressure oil for mechanical transmissions with viscosity grade SAE 80W90 and API grade GL5.
  • Page 55 Disc mower GMD802 Central gearbox draining Before draining oil, operate the machine for a few minutes so that the oil warms up. The angle gearbox is lubricated with 2.3 L (0.6 US gal) of SHELL SPIRAX A extreme-pressure oil for mechanical transmissions with viscosity grade SAE 80W90 and API grade GL5.
  • Page 56 Disc mower GMD802 Lubricate the following parts Oil: - The mowing unit lift cylinder ball joints (1). - The moving parts and pivot points. Grease: The mowing unit compensation cylinder ball joint (1). Maintenance and storage...

  • Page 57: Maintenance

    Disc mower GMD802 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. Hydro-pneumatic accumulators Before any work is carried out on a hydraulic circuit with hydro-pneumatic accumulator, depressurize the circuit.
  • Page 58 Disc mower GMD802 The side gearbox drive system Following all service operations on the drive system, check that the distance between the side gearbox drive shaft and the upper side of the cutterbar stiffener equals +/- 4 mm (0.15’’) measure A =577 mm (1’10’’)
  • Page 59 Disc mower GMD802 Work/transport cylinder Length in working position: Following all service operations on the transport/work cylinder, proceed to following adjustment: - Cylinder barrel (3) must be contact with frame stop (4). - Adapt cylinder length L to obtain a play J of 2 to 4 mm (0.08’’...
  • Page 60 Disc mower GMD802 Checking cutterbar oil level Regularly check the cutterbar oil level: • Place the cutterbar in horizontal position (with regards to X and Y axis). • Remove filler plug (1) and (2) as well as their seals. • Through filler plugs, check that the oil level (h) is comprised between 6 and 7 mm.
  • Page 61 Disc mower GMD802 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.
  • Page 62 Disc mower GMD802 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 distortion.

  • Page 63: Disc Replacement

    Disc mower GMD802 Knife replacement Replace knife lock-nuts and bolts when they have been removed 5 times. Replace immediately 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 64 Disc mower GMD802 Check if there is still a gap of 1 mm (0.04’’) between the disc lower part and the cutterbar wear plates. If this is not the case, fit one (maximum two) spacer(s) between the disc and the mounting hub (Part no.

  • Page 65: Storage

    Disc mower GMD802 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). - Touch up any areas of damaged paintwork. - Put the machine under cover in a dry place.

  • Page 66: Trouble Shooting Guide

    Disc mower GMD802 $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. Too low PTO speed (rotational Increase speed to 540 min frequency).

  • Page 67: Limited Warranty

    Disc mower GMD802 $Limited warranty Limited warranty...
  • Page 68 Disc mower GMD802 Limited warranty...

This manual is also suitable for:

Gmd802 series

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