KUHN GMD702F Operator'S Manual Download Page 65

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Troubleshooting guide

Disc mower

GMD702F

Troubleshooting guide



Problem



Cause



Remedy

Uneven stubble.

Dull or broken knives.

Replace knives.

Knives not installed correctly.

Make sure the arrow on the

knife upper face is pointing in
the disc's direction of rotation.

Too low PTO speed (rotational

frequency).

Increase speed to 540 min

-1

1000 min

-1

(depending upon

specification).

Soil build up in front of the

cutterbar.

Too much cutterbar down

pressure.

Adjust cutterbar ground

pressure.

Adjust main frame height with

regards to the ground.

Very wet working conditions.

Bad ground contour

adaptation.

Incorrect main frame setting.

Adjust main frame height with

regards to the ground.

Excessive ground speed.

Reduce groundspeed.

Insufficient air pressure in the

lift cylinders.

Adjust pressure.

Summary of Contents for GMD702F

Page 1: ...Original instructions KN121CGB D OPERATOR S MANUAL Disc mower GMD702F KN121CGB D English 11 2009 KN121CGB_D ...

Page 2: ......

Page 3: ... 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 are manufactured and carefully inspected in the same factory that builds the machine to assure high quality and accurate fitting of any necessary replacem...

Page 4: ... 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 19 Description and glossary 19 Technical specifications 20 Sound levels 20 Putting into service 21 Description of control elements 21 Coupling and uncoupling 21 ...

Page 5: ...djustments in working position 40 Machine use 43 Optional equipment 45 Quick release A frame coupler 45 1 3 8 21 spline yoke 45 Central gearbox 540 min 1 and 1000 min 1 46 Half pto shaft with friction slip clutch and free wheel 46 Raised skid shoes 47 Lighting and signalling device 47 Maintenance and storage 48 Frequency chart 48 Lubrication 49 Maintenance 54 Storage 62 Troubleshooting guide 63 Li...

Page 6: ...Disc mower 4 GMD702F Identification of the machine Identification of the machine 1 Front view 2 Rear view ...

Page 7: ...responding to the equipment fitted on your machine TYPE MASSE kg KUHN S A 67700 SAVERNE FRANCE N MADE IN FRANCE Kit no 1276870 Quick release A frame coupler Part no 4603187 1 3 8 21 spline yoke Central gearbox 1000 min 1 Part no 4603256 1 3 8 21 spline yoke Central gearbox 540 min 1 and 1000 min 1 Kit no 1036220 Central gearbox 540 min 1 and 1000 min 1 Kit no 1036310 Half pto shaft with friction s...

Page 8: ...s 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 This symbol is used to communicate technical information of particular interest ...

Page 9: ...y be operated maintained and repaired by competent persons who are familiar with machines specifications and operation and aware of safety regulations for 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 legislation concerning accident prevention work safety and p...

Page 10: ...ace and in good condition Immediately replace any worn or damaged guard 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 g...

Page 11: ...ances 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 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 roads ensure th...

Page 12: ...draulic 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 make visual inspection to check if hydraulic hoses are damaged or worn In case of normal wear the hydraulic hoses must be replaced every 5 years Damaged or worn hoses must immediately be replaced W...

Page 13: ...achine disengage the PTO drive turn off the engine remove ignition key and wait for all moving parts to come to a complete stop If the primary PTO shaft is equipped with a torque limiter 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 an...

Page 14: ...fety warning decals are placed in pictorial 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 the safety decals clean 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 dow...

Page 15: ...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 h...

Page 16: ...e 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 re...

Page 17: ...Safety Disc mower GMD702F 15 3 Location and description of safety decals on the machine Location of safety decals 599011001 6 3 5 4 5 59900300 3 1 2 599011001 6 3 59900300 4 5 ...

Page 18: ...r 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 Projections 3 Stones and other debris projected by the moving parts can travel a long distance The protection covers must always be in position and in good condition Always stay at a safe distance from the machine Crushing area 4 ...

Page 19: ...g 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 599011001 ...

Page 20: ...g to current safety regulations The front safety device comprises 2 signalling panels 1 2 white lights 2 2 white reflectors 3 The rear safety device comprises 2 signalling panels 1 2 red lights 4 2 red reflectors 5 Always keep to the legal speed limit for driving a tractor machine assembly on public roads The reflective panels are double sided 3 3 2 1 1 2 5 5 4 1 1 4 ...

Page 21: ... and glossary 0 1 Main frame 2 Mowing unit 3 Parking stand 4 Cutterbar 5 Transport lock 6 Side gearbox 7 Central gearbox 8 Parking stand operating lever 9 Side guard 10 Front guard 11 Lift cylinder 12 Suspension spring 13 Disk 14 Swathing drum 3 3 10 13 1 2 12 9 9 8 4 6 7 11 5 5 14 ...

Page 22: ...1 67 m 5 5 Height in transport position 1 33 m 4 4 Disc rotational speed 3011 min 1 PTO speed 1000 min 1 540 1000 min 1 depending upon specification Weight Approximately 805 kg 1775 lb Minimum PTO power requirement 36 kW 49 hp Swath width Approximately 1 10 m 3ft 7 3in Sound levels have been measured in accordance with the measuring methods as defined in NF EN ISO 4254 1 Agricultural machinery Saf...

Page 23: ... Coupling and uncoupling The machine adapts to tractors equipped with a front mounted 3 point lift linkage fitted with a quick release A frame coupler category A 2 Description of coupling elements A PTO shaft 1 3 8 6 splines 1 2 check chains 2 A hydraulic hose pressurizing the transport work position cylinder 3 A 7 pin electric plug for the electrical signalling equipment 4 optional equipment 1 3 ...

Page 24: ...emale plug The plug must be connected in parallel with the tractor lift cylinders in order to obtain simultaneous raising of the hydraulic linkage and the mowing unit For tractors fitted with a front lift linkage with double acting cylinders these must be set in detented float position to allow the lift linkage to travel up and down at will Modification work to the tractor s hydraulics must be und...

Page 25: ...ame coupler to the tractor s front lift linkage using the hitch pins supplied with the machine Part no 56618200 Attach check chains on hitch pins and secure using washers roll pins and lynch pins Adjust the top link length so that the A frame coupler is approximately vertical with regards to the ground ...

Page 26: ...chine lift cylinders Lower the tractor s lift linkage to tension the check chains Remove 2 bolts 2 Remove guard 1 Remove the secondary PTO shaft from the central gearbox Remove the mounting bolts 3 Invert drain plug 4 and vent plug 5 Pivot central gearbox 180 Reinstall the 4 mounting bolts 3 Torque to 12 daN m 89 lbf ft Couple the PTO shaft to the cover shaft Fit guard 1 Fit the 2 bolts 2 The two ...

Page 27: ...nit using the machine lift cylinders Lower the tractor s lift linkage to tension the check chains Remove 2 bolts 2 Remove guard 1 Remove the secondary PTO shaft from the central gearbox Remove the mounting bolts 3 Invert drain plug 4 and vent plug 5 Pivot central gearbox 180 Reinstall the 4 mounting bolts 3 Torque to 12 daN m 89 lbf ft Fit guard 1 Fit the 2 bolts 2 The two outer disks of the cutte...

Page 28: ...aft to the gearbox shaft according to the speed and direction of rotation of the tractor pto The pto guard 1 must be fitted on the output used to couple the shaft and cover 2 on the non used output 1000 099151001 1000 099152002 540 099149002 540 099150002 1 2 ...

Page 29: ...ng screw Tighten lock nut of stop mounting screw Coupling the machine With the machine in parking position Lower the tractor s lift linkage and couple the machine Lift the machine headstock using the tractor s front lift linkage Secure the A frame coupler lock using pin 1 Attach the primary pto shaft on the tractor s PTO stub Regularly check that stop is adjusted correctly especially each time the...

Page 30: ...n Connect the hydraulic hose to the single acting valve with float position Electrical connection optional equipment Connect 7 pin plug to the tractor Before connecting hoses to the tractor hydraulics ensure that tractor and machine circuits are not under pressure ...

Page 31: ...ce L of at least 25 mm 1 must be maintained When the PTO shaft is in its maximum extended position the tube overlap must be more than 250 mm 10 If this is not the case Mark length H to cut when the transmission is the maximum overlap position Shorten the guard tubes and the transmission tubes by the same length Bevel and clean the tubes Grease the inside of the outer tube Never operate the PTO sha...

Page 32: ...move the fragments of the bolt from the jaws Match the holes in the jaws Fit a new bolt 2 inside yoke Part no 80060850 Screw up and tighten the self locking nut moderately Part no 80200830 Reinstall cover 1 Immediately replace any worn or damaged guard 1 Before carrying out any maintenance or repairs on the machine switch off the tractor engine remove ignition key wait until all moving parts have ...

Page 33: ...actor s front linkage to position frame at approximately 210 mm 8 from the mowing unit Attach and lock safety chains on the highest tractor attachment position Lower the tractor s lift linkage to tension the check chains Check that measure 210 mm 8 is not modified Position A Parking stands disengaged Position B Parking stands engaged Refer to the decal fitted on the machine to check the distance b...

Page 34: ...ing position 1 on each machine side Lower the mowing unit using the machine lift cylinders Place lever 1 in position B parking stands 2 engaged Remove check chains on tractor side Disconnect the PTO shaft from the tractor Remove A frame coupler lock pin Position A Parking stands disengaged Position B Parking stands engaged 1 2 a b ...

Page 35: ...alling equipment plug in its holder 1 optional equipment Lower the tractor three point linkage to rest the machine on the ground Disconnect and store hydraulic hose on machine Lower the tractor s front linkage and uncouple the A frame coupler The machine is uncoupled 1 ...

Page 36: ...the working position Place lever 1 in position A parking stands 2 disengaged Activate tractor single acting valve to fully raise the machine Before placing the machine into transport position Wait until the rotating parts have come to a complete stop Position A Parking stands disengaged Position B Parking stands engaged 1 2 a b ...

Page 37: ...uctions for transport Disc mower GMD702F 35 Unlock and lift front guard using 18 box spanner supplied with the machine Remove tensioner 1 1 on each machine side Pivot side guards and lower lock front guard 1 ...

Page 38: ...osition 1 on each machine side The machine is in transport position Check that transport locks 1 are fully engaged The frame and mowing unit must go down simultaneously when the tractor lift cylinders are operated Never engage the tractor PTO drive when the machine is in transport position ...

Page 39: ... ensure that the machine complies with current highway code regulations Before driving onto a main road employ a person to give the driver indications to manoeuvre safely When leaving the farm On emerging roads At junctions Fit additional lights on the tractor if the original ones are covered by the machine see tractor dealer The additional lights must not be mistaken for the working lights fitted...

Page 40: ...e machine into work position From the transport position Lower the tractor s lift linkage to tension the check chains Position transport lock lever in working position 1 on each machine side Pivot side guards and lower lock front guard Insert side guard tube 1 in frame end 2 1 2 ...

Page 41: ... mounting brackets Make sure all the guards are in place Activate machine lift cylinders to rest the machine on the ground Shift the mowing unit lift cylinder directional control valve in float position The machine is in working position Immediately replace any worn or damaged guard 1 ...

Page 42: ...ace the machine in parking position Remove check chains on tractor side Place lever 1 in position B parking stands 2 engaged Lower tractor front linkage until frame rests on its parking stands and the machine rests on the ground Modify the top link length to alter the machine tilt angle Check cutting height Position A Parking stands disengaged Position B Parking stands engaged If the tractor is fi...

Page 43: ...tting height L1 80 mm 3 1 is obtained when the discs are parallel to the ground The minimum cutting height must not be below L2 30 mm 1 1 Too low a cutting height can lead to Excessive disc and knife wear Crop being contaminated by soil Delay in regrowth L1 L2 ...

Page 44: ...ng setting can be altered Place the machine in transport position Loosen counter nut 2 Rotate screw 3 to increase or decrease the mowing unit ground pressure Tighten counter nut 2 The mowing unit is suspended by means of floatation springs 1 The measure X is factory set at 50 mm 1 96 in Adjust both sides to the same setting 2 3 X 1 ...

Page 45: ...oading harvester we recommend to reduce the pto speed by a 1 3 This allows better crop rearward ejection and avoids the self loading harvester to over rev Drive speed Before mowing and to reduce risks of projections lower side guards and front hood Fit rear cover tensioners to swath shield screws Keep all persons and animals away from the machine danger zone Never lean or step on the guards Never ...

Page 46: ...g components for damage Lower and lock front guard Check that torque limiter is functioning 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 Before carrying out any maintenance or repairs on the machine switch off the tractor engine remove ignition key wait unti...

Page 47: ...o 1276870 For tractors not equipped with a quick release A frame coupler ISO 11001 2 1 3 8 21 spline yoke Part no 4603187 Central gearbox 1000 min 1 Part no 4603256 Central gearbox 540 min 1 and 1000 min 1 A specific yoke is available as option for tractors equipped with a 1 3 8 21 spline pto stub ...

Page 48: ...given in the present operator s manual 4 Half pto shaft with friction slip clutch and free wheel Kit no 1036310 The secondary pto shaft can be fitted with a friction slip clutch and a free wheel Apply the safety and maintenance instructions stipulated in the manual supplied with the transmission Lubrication Every 250 hours U joints 1 The torque limiter 2 Place the machine in working position Stop ...

Page 49: ...pment enables obtaining a fixed cutting height of 55 mm 2 2 and easy machine uncoupling without having to touch the top link 6 Lighting and signalling device Kit no 1076110 The light and signalling kit provides increased safety during transport on public roads The use of raised skid shoes is also recommended on sticky grounds ...

Page 50: ... 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 After the first 10 hours of use Every 50 hours Every 200 hours or at the end of the season Oil change Cutterbar Side gearbox Central gearbox Oil The moving parts and pivot points ...

Page 51: ...tion 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 52: ...shaft Every 8 hours U joints 1 transmission tube 2 Guide rings 3 Secondary PTO shaft Remove cover 1 to access greasers Every 250 hours U joints 1 The torque limiter 2 Place the machine in working position Stop the tractor engine and remove ignition key 1 1 3 3 2 1 1 2 1 ...

Page 53: ...ssary Pour the correct oil quantity and quality through the opening of the filler plug Clean and reinstall filler plug 2 and its washer Reassemble the unit Before draining oil operate the machine for a few minutes so that the oil warms up The cutterbar is lubricated with 2 L 0 52 US gal of extreme pressure gear oil with viscosity grade SHELL SPIRAX A and SAE 80W90 grade API When draining and refil...

Page 54: ... oil level The MAX level corresponds to the mark on the dipstick plug The MIN level corresponds to the end of the dipstick plug Before draining oil operate the machine for a few minutes so that the oil warms up B A 1 2 3 The angle gearbox is lubricated with 0 7 L 0 18 US gal of SHELL SPIRAX A extreme pressure oil for mechanical transmissions with viscosity grade SAE 80W90 and API grade GL5 When dr...

Page 55: ... mark on the dipstick plug The MIN level corresponds to the end of the dipstick plug Before draining oil operate the machine for a few minutes so that the oil warms up B A 1 2 The main gearbox is lubricated with SHELL SPIRAX A extreme pressure gear oil with viscosity grade SAE 80W90 and API grade GL5 Quantity Central gearbox 1000 min 1 0 5 L 0 13 US gal Central gearbox 540 min 1 and 1000 min 1 0 6...

Page 56: ...s tangent with washer 3 Loosen counter nut 4 If necessary tighten tensioning bolt 5 Tighten counter nut 4 Reinstall cover 1 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 Slackened belts slip reduce the crop ejection quality and cause cutterbar clogging 1 4 5 ...

Page 57: ...ing unit to immediately react to ground unevenness Check the pressure Place the machine in working position Shift the mowing unit lift cylinder directional control valve in float position Connect pressure gauge 1 to connector 2 Check the pressure given on the gauge The pressure must be of 3 5 bar 50 psi when the cylinder rods are fully extended ...

Page 58: ...lugs and their seals 1 and 2 replace them if necessary If in doubt as to the oil quantity contained in the cutterbar fully drain and refill cutterbar respecting recommended oil quantity and quality Before checking that the discs rotate freely by hand If it is found that the transmission case is very hot to touch by hand there is no cause of alarm provided Lubrication recommendations have been resp...

Page 59: ...ollowing cases Damaged knives Very rough conditions can cause knives to crack and become deformed Worn knives Knife length C must exceed 65 mm 2 6 Knife width B measured at a distance A of 10 mm 0 4 from the disc edge must exceed 34 mm 1 4 The hole L for the securing bolt must not become oval by more than 20 mm 0 8 Immediately replace worn or damaged parts with genuine KUHN parts Always replace bo...

Page 60: ... or inoperational When the bolt head wear reaches the center line of the bolt When diameter D of the bolt shoulder is less than 15 mm 0 6 After having been removed 5 times Replace nuts in the following cases When the contact washer has lost its elasticity When the contact washer loosens itself from the nut When nut wear reaches a 5 mm 0 2 After having been removed 5 times Check the condition of th...

Page 61: ...c to use the other cutting edge or replaced On each knife an arrow indicates the disc s direction of rotation Make sure that the securing nut and bolt are in good condition and if necessary replace them Torque knife locknut to 12 daN m 89 lbf ft Dull knives require more horse power and have a negative effect on the cut quality Replace knife lock nuts and bolts when they have been removed 5 times R...

Page 62: ...e the 2 other nipple screws and their spring washers Remove the disc When remounting Position their largest diameters at right angles to each other Position conical centre of spring washer at the top Tighten screws Torque 12 daN m 89 lbf ft 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 betwe...

Page 63: ...Maintenance and storage Disc mower GMD702F 61 Outer cones Check torque of outer cover mounting bolts 1 6 daN m 44 lbf ft Replace any lost or damaged cover 2 Part no 56806610 2 1 ...

Page 64: ...as of damaged paintwork Put the machine under cover in a dry place Inspect and replace worn knives and bolts see section Inspection of knives and securing elements Slacken V belts and check their condition At the start of each season Re read the operators manual Check that all nuts and bolts are sufficiently tightened Retension V belts Make sure that all protection devices are in place and in good...

Page 65: ...onal frequency Increase speed to 540 min 1 or 1000 min 1 depending upon specification Soil build up in front of the cutterbar Too much cutterbar down pressure Adjust cutterbar ground pressure Adjust main frame height with regards to the ground Very wet working conditions Bad ground contour adaptation Incorrect main frame setting Adjust main frame height with regards to the ground Excessive ground ...

Page 66: ...tional frequency Increase speed to 540 min 1 or 1000 min 1 depending upon specification Insufficient cutterbar ground clearance in headland turn position Incorrect tractor lift linkage setting See machine attachment Poor crop ejection during downhill mowing at reduced ground speed PTO speed is too high Reduce pto speed by approximately a 1 3 ...

Page 67: ...r concerned in as much as the latter justifies such a claim This Limited Warranty does not apply to failure through normal wear and tear to damage resulting from negligence or from lack of inspection from misuse from lack of maintenance and or if the machine has been involved in an accident lent out or used for purposes other than those for which it was intended by the Company This Limited Warrant...

Page 68: ...ty of lubricants used must always be in accordance with Company specifications The safety measures mentioned in the Operator s manual and on the machine itself have been followed and all the guards and protective elements of whatever nature have been inspected regularly and maintained in perfect working order The judgment of the Company in all case of claims under this Limited Warranty shall be fi...

Page 69: ...nforms to the requirements of following European harmonized standards conforms to the requirements of the European directive 2006 42 CE Brand Brand Machine Machine Type Model Type Model Serial no Serial no declares that the product described hereafter Manufacturer name and address The manufacturer Name and address of the person authorised to compile the technical file 2 y r o t a n g i S 1 y r o t...

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Page 72: ...CHARD SAS 24 route de Nantes F 44680 CHEMERE FRANCE KUHN HUARD S A B P 49 F 44142 CHATEAUBRIANT CEDEX FRANCE KUHN GELDROP B V P O Box 9 5660 AA GELDROP THE NETHERLANDS KUHN NORTH AMERICA INC P O Box 167 Brodhead WI 53520 USA KUHN KRAUSE INC PO Box 2707 Hutchinson KS 67504 USA KUHN DO BRASIL S A PASSO FUNDO RS 99050 130 BRASIL KUHN MONTANA SÃO JOSÉ DOS PINHAIS PR 83025 410 BRASIL ...

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