KUHN GMD44 Operator'S Manual Download Page 55

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GMD44 _760001 _xxxxxx

Gearbox

Required equipment

Preliminary operations

Changing angle gearbox oil

Operating procedure

Upstream operations

Step 1.
Remove the gearbox

Remove cutterbar from the chassis.
Remove 4 bolts (1).
Remove brackets (2).
Remove side skids (3).

Page 55/95

Printing date : 06-02-2014

GMD44_760001_xxxxxx

©Copyright KUHN S.A.

Summary of Contents for GMD44

Page 1: ...GMD44 _760001 _xxxxxx Last update Release date 17 01 2014 17 20 45 Revision index Page 1 95 Printing date 06 02 2014 GMD44_760001_xxxxxx C o p y r i g h t K U H N S A...

Page 2: ...2 Disk with cone 3 Knives 4 Disk housing 5 Swath shield holder 6 Upper gear case 7 Set of gearwheels 8 Lower gear case 9 Guard angle bracket 10 Disk skid 11 Wear skids 12 Reinforcements 13 Angles Pag...

Page 4: ...by the manufacturer and using only genuine spare parts equipment and accessories as recommended by the manufacturer The manufacturer is not held liable for any damage resulting from machine applicatio...

Page 5: ...ns to take before using the machine Do not wear loose clothing which could become caught up in moving parts Wear appropriate protective clothing gloves shoes goggles helmet ear defenders etc Ensure th...

Page 6: ...ne 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...

Page 7: ...ional information 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 Be...

Page 8: ...Do not stand between the tractor and the machine without ensuring that the parking brake is applied Hydraulic circuit Caution The hydraulic circuit is under high pressure Maximum pressure at work 200...

Page 9: ...nd wait until all moving parts have come to a complete stop PTO shaft Use only PTO shafts supplied with the machine or recommended by the machine manufacturer The protective shield of the tractor PTO...

Page 10: ...s stopped When uncoupling the machine rest the PTO shaft on the support specially provided and replace protective shield on the PTO stub of the tractor Read and follow the instructions in the operator...

Page 11: ...dition Safety decals Safety warnings are placed in safety decal form on various parts of the machine They are there to warn you of potential dangers and to tell you how to avoid accidents Always keep...

Page 12: ...ttached 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...

Page 13: ...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 replac...

Page 14: ...structions of the present manual Check the guards regularly Immediately replace any damaged or missing elements Before engaging the pto drive lower the rotors onto the ground Make sure all the guards...

Page 15: ...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 tool...

Page 16: ...be applied to calculate the minimum ballasting at the front IF min which enables obtaining a weight on the front axle equal to 20 of the tractor s tare The calculation takes into account the rear moun...

Page 17: ...center of gravity b m Tractor wheelbase c m Distance between the rear axle center and the center of the lower links d m Distance between the center of the lower links and the center of gravity of the...

Page 18: ...44 _760001 _xxxxxx Maintenance plan Copyright 2012 KUHN S A Cutterbar draining and refilling Lateral gearbox draining Page 18 95 Printing date 06 02 2014 GMD44_760001_xxxxxx C o p y r i g h t K U H N...

Page 19: ...f viscosity SAE90 in the cutterbar Before draining oil operate the machine for a few minutes so that the oil warms up Step 1 The cutterbar is lubricated with 1 750 46 of extreme pressure gear oil with...

Page 20: ...the correct oil quantity and quality through the opening of the filler plug The oil must reach the lower edge of the filling hole Clean and reinstall filler plug 1 and its washer Replace if necessary...

Page 21: ...ith 0 250 06 of SHELL SPIRAX extreme pressure oil for mechanical transmissions with viscosity grade SAE 80W90 and API grade GL5 When draining and refilling it is recommended to use either a mineral ba...

Page 22: ...e machine in working position Pour the correct oil quantity and quality through the opening of the filler plug Checking the oil level The oil level must reach the lower edge of the emptying hole Clean...

Page 23: ...N S A From the working position Remove breather plug 1 Clean and check breather plug for good functioning Reinstall breather plug 1 Page 23 95 Printing date 06 02 2014 GMD44_760001_xxxxxx C o p y r i...

Page 25: ...extractor Bronze rod Preliminary operations Cutterbar draining and refilling Operating procedure Upstream operations Step 1 Remove disks Place a wooden wedge between two disks to stop them from rotat...

Page 26: ...asher 2 On cone disks Reinstall plug 1 Remove nut 2 Remove spring washer 3 Note the direction of the spring washer Note the direction of the spring washer Step 2 Page 26 95 Printing date 06 02 2014 GM...

Page 27: ...n of fender washer For easier removal use levers on either sides of the disk Step 1 Parking Remove cutterbar from the chassis Remove 4 bolts 1 Remove brackets 2 Remove side skids 3 Page 27 95 Printing...

Page 28: ...move compensation volume 6 Remove wavy washer 7 Step 2 Remove disk guards Remove 2 bolts 1 Remove bolt 2 and nut 3 Remove disk guard 4 Remove spacer 5 Note the number and position of the spacers See s...

Page 29: ...th board holder 5 Step 4 Remove bolts and nuts Remove the reinforcement brackets Remove wear plates Note position of mounting bolts disk skids and reinforcements See sheet Step 5 To avoid accidents bl...

Page 30: ...lower gearcase o ring 2 To prevent damaging the threads and jamming the nylon bush on the bolt Loosen mounting bolts 1 of a few turns going from the cutter bar oustide towards the center Step 6 Page...

Page 31: ...housing 2 Remove o rings 3 and 4 Note position of helical pinions Step 7 Remove bearings 1 and 2 with a bearing extractor Specific tools Part no 83450009 Remove o ring 3 Remove spacer 4 Remove O ring...

Page 32: ...gearwheels Remove intermediate gearwheel 1 using 2 crowbars or levers Remove nylon bushes 1 Note the position of the intermediate gearwheels Page 32 95 Printing date 06 02 2014 GMD44_760001_xxxxxx C o...

Page 33: ...ove bearing 2 Remove bearing 3 Remove spacer 4 Remove circlip 5 From 786384 to Remove snap rings 1 and 2 Remove bearing 3 See sheet Step 9 Remove drive shaft Page 33 95 Printing date 06 02 2014 GMD44_...

Page 34: ...Remove circlip 1 Remove bearing 2 Step 10 Replace all parts that are worn or damaged with KUHN original parts Step 1 Fitting Clean components before reinstalling them Page 34 95 Printing date 06 02 2...

Page 35: ...1 How to fit a retaining ring Reinstall drive shaft 2 Reinstall retaining ring 1 Use appropriate tools to fit the bearings Step 2 Reinstall disk bearing housings Page 35 95 Printing date 06 02 2014 GM...

Page 36: ...Torque 752 Reinstall bearings with the protected part towards the outside of the disk housing Step 3 Reinstall helical pinions 1 Respect left and right helical pinion fitting position according to the...

Page 37: ...fully Reinstall spacers with the bevelled part downwards Step 5 Reinstall intermediate gearwheels From 760001 to 786383 Reinstall retaining ring 5 Reinstall spacer 4 Insert bearing 3 fully Insert bea...

Page 38: ...ow tube of diameter smaller than the inner bearing cage The blue retaining ring must be able to nest itself into the hollow part of the punch used Before reinstalling the intermediate pinions position...

Page 39: ...Position o ring 2 on lower half gearcase Glue the 4 o ring ends with quick setting glue Position upper half casing over lower half casing Reinstall 2 bolts on the ends to maintain half casings in pos...

Page 40: ...lts reinstall temporarily several disks rotate them by hand and check disk synchronization Step 7 Guard angle bracket Reinstall swath board holder 5 Reinstall guard angle bracket 4 Reinstall the 3 bol...

Page 41: ...bolts disk skids and reinforcements See sheet Step 9 Reinstall disk guards Reinstall disk skid 4 and spacer 5 Reinstall bolt 2 and nut 3 Reinstall the 2 bolts 1 Torque 8 564 Note the number and posit...

Page 42: ...einstall angle gearbox 3 Reinstall the 8 bolts 1 and nuts 2 Torque 1289 Reinstall side skid 3 Reinstall the 2 brackets 2 Reinstall the 4 bolts 1 Reinstall cutterbar on the chassis Step 11 Reinstall di...

Page 43: ...ect disk direction of rotation according to fitting of knives On each knife an arrow indicates the disk s direction of rotation Make sure that the securing nut and bolt are in good condition and if ne...

Page 44: ...wo disks to stop them from rotating Position conical center of spring washers at the top Reinstall spring washer 2 Reinstall nut 1 Torque 18133 Page 44 95 Printing date 06 02 2014 GMD44_760001_xxxxxx...

Page 45: ...12 KUHN S A On cone disks Reinstall spring washer 3 Reinstall nut 2 Torque 18133 Reinstall plug 1 Step 1 Pour required oil quantity in the cutter bar Page 45 95 Printing date 06 02 2014 GMD44_760001_x...

Page 46: ...inary operations Operating procedure Upstream operations Bearings are precisely matched do not invert inner races Step 1 Remove gearwheel of intermediate wheel Page 46 95 Printing date 06 02 2014 GMD4...

Page 47: ...le close to its opening with a chisel Step 2 Place intermediate gearwheel in a vise Stop the snap ring from rotating by using locking pliers Step 3 Page 47 95 Printing date 06 02 2014 GMD44_760001_xxx...

Page 48: ...osition small screwdriver at 90 degrees with regardsto the first screwdriver Step 4 Remove larger screwdriver Press small screwdriver until snap ring is opened Pivot screwdriver to free snap ring from...

Page 49: ...an intermediate gearwheel Step 2 Reinstall new bearing Insert bearing in its housing Use an old bearing cage or an adequate bush Insert and tighten the unit in a vise or a press Page 49 95 Printing da...

Page 50: ...S A Position snap ring in intermediate gearwheel groove Check that the snap ring functions properly by rotating it using a screwdriver Page 50 95 Printing date 06 02 2014 GMD44_760001_xxxxxx C o p y r...

Page 51: ...ing ring Operating procedure Main operations Copyright 2012 KUHN S A Step 1 When fitting a retaining ring position the small lug diameter on the plier side Page 51 95 Printing date 06 02 2014 GMD44_76...

Page 52: ...ositioning of the helical pinions Copyright 2012 KUHN S A Mark Function a Right helical drive pinion b Left helical pinion c Right helical pinion Page 52 95 Printing date 06 02 2014 GMD44_760001_xxxxx...

Page 53: ...the other helical pinions alternately Copyright 2012 KUHN S A Before reinstalling the intermediate pinions position helical pinions making sure to respect the disk synchronization Marks on tooth and i...

Page 54: ...ement of the Nylon bushes Inser nylon bush 1 manually Use screw 1 and hammer 2 to fully insert nylon bush 3 delicately Copyright 2012 KUHN S A Page 54 95 Printing date 06 02 2014 GMD44_760001_xxxxxx C...

Page 55: ...Changing angle gearbox oil Operating procedure Upstream operations Step 1 Remove the gearbox Remove cutterbar from the chassis Remove 4 bolts 1 Remove brackets 2 Remove side skids 3 1 Page 55 95 Prin...

Page 56: ...uts 2 Remove the gearbox 3 Remove the chock 4 Remove O ring 5 Remove compensation volume 6 Remove wavy washer 7 Step 1 Parking Remove key 1 Remove 6 bolts 2 Page 56 95 Printing date 06 02 2014 GMD44_7...

Page 57: ...Remove seal 2 Remove spacer 1 Remove o ring 2 Remove shim rings 3 Note number and position of shim rings Step 2 Remove 6 bolts 1 Page 57 95 Printing date 06 02 2014 GMD44_760001_xxxxxx C o p y r i g h...

Page 58: ...e unit 1 Remove seal 2 Step 3 Remove cover 1 Remove shim rings 2 Remove O ring 3 Note number and position of shim rings Page 58 95 Printing date 06 02 2014 GMD44_760001_xxxxxx C o p y r i g h t K U H...

Page 59: ...Remove gearwheel 2 from shaft Remove key 3 Step 4 Remove circlip 1 Remove o ring 2 Remove circlip 3 Remove unit 4 Remove bearing 1 Page 59 95 Printing date 06 02 2014 GMD44_760001_xxxxxx C o p y r i...

Page 60: ...ug 1 Step 6 Replace all parts that are worn or damaged with KUHN original parts Step 1 Fitting Reinstall seal 1 Reinstall cover 2 Reinstall the 6 bolts 3 Torque 644 Page 60 95 Printing date 06 02 2014...

Page 61: ...bearing 1 Reinstall unit 4 Reinstall retaining ring 3 Reinstall oil seal 2 Reinstall retaining ring 1 How to fit a retaining ring Step 3 Page 61 95 Printing date 06 02 2014 GMD44_760001_xxxxxx C o p y...

Page 62: ...l bearings 3 Reinstall shim rings 4 Spacing principle Reinstall unit 1 Reinstall shim rings 1 Spacing principle Reinstall seal 2 Reinstall cover 3 Reinstall the 6 bolts 4 Torque 644 Page 62 95 Printin...

Page 63: ...the shaft does not rotate remove shim ring and repeat check If the longitudinal play remains add a shim ring and repeat check Step 5 Reinstall O ring 1 Reinstall spacer 2 Reinstall oil seal 3 Knife n...

Page 64: ...6 Reinstall angle gearbox 3 Reinstall the 8 bolts 1 and nuts 2 Torque 1289 Reinstall side skid 3 Reinstall the 2 brackets 2 Reinstall the 4 bolts 1 Reinstall cutterbar on the chassis Step 1 Fill gearb...

Page 66: ...A Step 1 Spacing principle Fit thickest spacer against smallest contact area Fit the second thickest spacer against the largest contact area or the retaining ring Position spacers betwen the two other...

Page 68: ...0001 _xxxxxx Adjustment Copyright 2012 KUHN S A Assembly positioning of the helical pinions Replacement of the Nylon bushes Page 68 95 Printing date 06 02 2014 GMD44_760001_xxxxxx C o p y r i g h t K...

Page 69: ...1 _xxxxxx Component test Copyright 2012 KUHN S A Bolt and nut torque chart Spacers How to fit a retaining ring Fixing elements Page 69 95 Printing date 06 02 2014 GMD44_760001_xxxxxx C o p y r i g h t...

Page 70: ...bolts ISO 898 1 Dimensions of hex head screws in accordance with ISO 4014 to ISO 4018 Dimensions of the pan head screws in accordance with ISO 4762 Protection against corrosion electrolytic zinc depo...

Page 72: ...s visible distortion When the locking compound is worn or inoperational When the bolt head wear reaches the center line of the bolt When diameter D of the bolt shoulder is less than 150 6 After having...

Page 73: ...having been removed 5 times Check the condition of the fixing elements regularly and also the torque of the knife fixing bolt Torque nut to 1289 Page 73 95 Printing date 06 02 2014 GMD44_760001_xxxxxx...

Page 74: ...60001 _xxxxxx Technical documentation Copyright 2012 KUHN S A Spare parts catalogue 9014168 18 Operator s manual 95011AUS Page 74 95 Printing date 06 02 2014 GMD44_760001_xxxxxx C o p y r i g h t K U...

Page 75: ...N S A Description of menus Description of safety decals Animation user guide SVG format illustration user guide Video user guide Browsing principle for trouble shooting sheets Page 75 95 Printing date...

Page 76: ...cation of the machine s main components Technical specifications Description of the machine s technical specifications Preparations for putting into service Handling Machine anchoring points and crate...

Page 77: ...e adjustments Control Operating procedures for the various checking of machine functions components Maintenance and repairs Maintenance plan Frequency chart and maintenance sheet Parts replacement Ope...

Page 78: ...tions Kuhnitech operating procedures Documentation charter Technical questions Information request or comment form on the technical content of the site Page 78 95 Printing date 06 02 2014 GMD44_760001...

Page 79: ...andard sheet Standard Standard sheet Pre delivery instructions Standard sheet Installing options Standard sheet Adjustment Standard sheet Control Standard sheet Maintenance Standard sheet Replacement...

Page 80: ...on Paint Specific tools Cleaning tools Clamping tools Electric measuring tools Measuring tools Electric repair tools Hammer Greasing tools Lifting gear Wrenches Page 80 95 Printing date 06 02 2014 GMD...

Page 81: ...iption Hazardous gases Cutting of fingers Toxic substances Pollution Fire Explosion High pressure fluid injection into body Entanglement tedder rake Finger entanglement Page 81 95 Printing date 06 02...

Page 82: ...rso Force applied from side Crushing of hand force applied from above Crushing of whole body Force applied from above Cutting of foot Cutting of fingers or hand Falling Slipping on wet area Caustic li...

Page 83: ...HN S A Drive Video SVG format illustration Link Transfer to new sheet Download a PDF Download an executable New sheet Sheet update Page 83 95 Printing date 06 02 2014 GMD44_760001_xxxxxx C o p y r i g...

Page 84: ...s are composed of a yellow background and a central purple icon The purple color indicates that it is a clickable button When browsing The mouse pointer changes into a hand The purple icon becomes blu...

Page 85: ...tion Links are always displayed in purple color The purple color indicates that it is a clickable link When browsing The mouse pointer changes into a hand The link purple symbol becomes blue The blue...

Page 86: ...e current position of the control box area selector The purple links are clickable 2 The purple area links 2 are clickable 3 The links of area 3 are grey and inactive Symbol Description This symbol is...

Page 87: ...ription of electric wire connection Zoom on the connector terminal of the machine wiring harness and the on the wire color a Description of the wire connection at splicing level Zoom on the electric w...

Page 88: ...the hydraulic part The hydraulic diagram animation is split in stages Each stage corresponds to a function Operating principle Corresponding solenoid valve highlighted on hydraulic valve bank d Page...

Page 89: ...mponents operated by the function appear in color a Color arrows indicate the direction in which the oil flows in the hydraulic circuit Zoom on the connection of hydraulic hoses b Page 89 95 Printing...

Page 90: ...ulic valve bank supply pressure T Return to tank pressure Zoom on the animation of the machine movement with regards to the function selected e Copyright 2012 KUHN S A Page 90 95 Printing date 06 02 2...

Page 91: ...nables interaction with the video 1 scroll bar that enables to view your position with regards to the length of the video Video player description 1 Pause 2 Skip to start 3 Fast rewind 4 Play 5 Fast f...

Page 92: ...zoom in Press key Ctrl and select part of the picture using the mouse pointer To zoom out Press keys Ctrl Shift and click on picture to decrease the zoom percentage For a precise zoom out Press keys C...

Page 93: ...tered character string 2 is displayed Click on link 3 to access trouble shooting Trouble shooting The trouble shooting sheets present a list of facts and or operations links to be made in ascending or...

Page 94: ...Yes to go to the next stage Click on icon No when described operations have been respected but do not solve the breakdown Either the stage provided the solution for the breakdown and closes the proce...

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