KUHN GMD800GII-FF Operator'S Manual Download Page 61

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Maintenance and storage

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.
- When the locking compound is worn or inoperational.
- When diameter D of the bolt shoulder is less than

11 mm (0.43’’).

See section: ’’Disc replacement’’.

The radial play between a worn bolt and a new
knife must not exceed d = 10 mm (0.4’’).

Summary of Contents for GMD800GII-FF

Page 1: ...KN198KGB D OPERATOR S MANUAL Disc mower GMD800GII FF KN198KGB D English 04 2010...

Page 2: ......

Page 3: ...O OPERATE 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 c...

Page 4: ...6 Safety instructions 7 Location and description of safety decals on the machine 17 Road safety equipment and recommendations 22 Machine specifications 23 Description and glossary 23 Technical specifi...

Page 5: ...ent 45 Raised skid shoes 45 Side deflector 45 Side deflector with high cone disk 46 Lighting and signalling 46 Lateral signalling equipment 47 1000 min 1 drive kit 48 Longer hitch pins 49 Maintenance...

Page 6: ...Disc mower 4 GMD800GII FF Identification of the machine Identification of the machine 1 Front view 2 Rear view...

Page 7: ...spare parts orders Type GMD800GII Serial no 4 Optional equipment Tick box corresponding to the equipment fitted on your machine Kit no 1036230 Raised skid shoes 90 mm 3 54 Kit no 1036340 Side deflecto...

Page 8: ...es 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 r...

Page 9: ...only 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 imp...

Page 10: ...place 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...

Page 11: ...ll legally required lightings and signallings are in place Ensure that lightings and signallings are clean and in good working order Replace any missing or broken equipment Gross weight and weight per...

Page 12: ...oads with empty hoppers and tanks Description Units Description T kg Tractor unladen weight PTAC kg Gross Combined Weight Rating T1 kg Unladen load on tractor front axle T2 kg Empty load on tractor re...

Page 13: ...g 3300 lb Add ballast weights until the minimum front axle load is exceeded Repeat checking procedure Stage 3 To measure Total weight t Tractor machine transport position Ballast weights Checking To g...

Page 14: ...aximum allowed tractor rear axle load Check that tyre and rim specifiations are in conformity with the requirements of the tractor manufacturer Example Load on rear axle t2 8500 kg 18740 lb Check in t...

Page 15: ...ure Before disconnecting a hose depressurize the hydraulic circuit To avoid making incorrect connections mark hydraulic couplers and corresponding hoses with colors WARNING Functions could be reversed...

Page 16: ...n the machine disengage the PTO drive turn off the engine remove ignition key and wait for all moving parts have come to a complete stop If the primary PTO shaft is equipped with a slip clutch or a fr...

Page 17: ...afety 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 c...

Page 18: ...s pressure accumulators etc must only be carried out by competent persons with regulation equipment Wear the appropriate protective clothing for the work in hand gloves shoes goggles helmet ear defend...

Page 19: ...missing cutting tool or element To do this use the tool outfit supplied with the machine For your safety only use genuine parts Regularly check the condition of the protection covers Immediatly replac...

Page 20: ...Disc mower 18 GMD800GII FF Safety...

Page 21: ...chine 2 Before leaving the tractor or before adjusting maintaining or repairing the machine disengage the PTO drive turn off the engine remove ignition key and wait until all moving parts have come to...

Page 22: ...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 Cutting tools 7...

Page 23: ...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 Lower the machine The machine...

Page 24: ...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 as...

Page 25: ...800GII FF 23 Machine specifications 1 Description and glossary 0 1 Cutterbar 2 Parking lock 3 Front guard 4 Check chain 5 Release cord 6 Hitch pin 7 Gearbox 8 Lift cylinder 9 Compensating spring 10 Up...

Page 26: ...1 635 m 5 4 Height in transport position 3 665 m 12 Length in transport position 1 38 m 4 63 Disc rotational speed 2986 min 1 PTO speed 540 min 1 Weight 710 kg 1565 lb Minimum PTO power requirement 41...

Page 27: ...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 maintena...

Page 28: ...tractor The tractor PTO stub must rotate at a speed of 540 min 1 The tractor must be fitted with a single acting hydraulic outlet with float position Check that the tractor s authorized gross weight...

Page 29: ...GMD800GII FF 27 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...

Page 30: ...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 Loosen the 8 screws 3 Position hitch pin 1 at measure...

Page 31: ...Torque 12 daN m 89 lbf ft Position hitch pin 2 at measure X 825 mm 2 8 Tighten 4 hitch pin screws 2 Torque 12 daN m 89 lbf ft If measure A is comprised between 2 25 m 7 04 and 2 40 m 7 10 Place lower...

Page 32: ...s Attach the lower links to the hitch pins Secure each hitch pin with lynch pin Attach top link 1 in one of the upper holes on the tractor side Insert and lock top link lynch pin Place release cord ha...

Page 33: ...ervice Disc mower GMD800GII FF 31 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 an...

Page 34: ...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 th...

Page 35: ...ach hook of check chain supplied with the machine in one of the upper holes of the tractor top link yoke Lower the machine until the check chain is under tension Respect a lift stop functional play A...

Page 36: ...in holder 1 Disconnect hydraulic hose Position hydraulic hose on holder 2 Remove cord from tractor and store it in its holder on the machine Detach the top link from the machine end Release the lower...

Page 37: ...t work cylinder to bring the mowing unit in transport position As cutter bar is being pivoted wait until lift stop end 1 passes over lock 2 and release cord The machine automatically locks in transpor...

Page 38: ...ment is clean before going on public roads Never engage the tractor PTO drive when the machine is in transport position Before driving the machine on public roads ensure that the machine complies with...

Page 39: ...rd until transport lock is released Lower the mowing unit onto the ground using the mowing unit lift cylinder Press lock 1 and lower front guard 2 The guard locks automatically Before placing the mach...

Page 40: ...he 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...

Page 41: ...ify the top link length to alter the machine tilt angle Check cutting height Before leaving the tractor or before adjusting maintaining or repairing the machine disengage the PTO drive turn off the en...

Page 42: ...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...

Page 43: ...ase measure X to reduce suspension Tighten counter nut 2 3 Machine use Before the machine engages the crop Engage the tractor PTO and slowly increase the speed up to 540 min 1 The mowing unit is suspe...

Page 44: ...rt work cylinder control valve in the pivot into transport position The cylinder lock 1 bottoms Adapt the forward speed to the working conditions Operate the cutterbar using the pivot into transport w...

Page 45: ...rear when hitting an obstacle The safety breakback is reset by reversing a Before carrying out any maintenance or repairs on the machine switch off the tractor engine remove ignition key wait until a...

Page 46: ...rd Remove foreign body Check that the mowing unit has not been damaged Check rotating components for damage Lower and lock front guard Respect spring washer layout For normal functioning of the break...

Page 47: ...ng higher between 35 and 90 mm 1 4 3 5 Replace the end disc skids by the 2 raised skid shoes 2 Side deflector Kit no 1036340 The side deflectors enables mowing dense or down crops with long stems Fit...

Page 48: ...apping around the outer large cone disk when mowing in dense or down crops with long stems 4 Lighting and signalling Kit no 1026100 The machine can be fitted with specific signalling lights to comply...

Page 49: ...lling 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 Th...

Page 50: ...Optional equipment 1 on each machine side 1 in combination with signalling panel 6 1000 min 1 drive kit Kit no 1066010 Belt and pulley assembly for tractors with a pto speed of 1000 min 1 Lighting and...

Page 51: ...tment 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 Position hitch pin 2 at measure H 10 mm 0 4 Tighten 4 hitc...

Page 52: ...ctor engine remove ignition key wait until all moving parts have come to a standstill and apply park brake Maintenance intervals are indicated for normal conditions of use After the first 10 hours of...

Page 53: ...PTO shaft Primary PTO shaft Every 8 hours universal joints 1 Every 20 hours transmission tube 2 Every 40 hours guide rings 3 Lubricate with SHELL multi purpose grease grade NLGI 2 Place the machine in...

Page 54: ...x oil level The oil level must reach the lower edge of the emptying hole Clean and reinstall drain plug 2 and its washer Clean and reinstall filler plug 1 and its washer Before draining oil operate th...

Page 55: ...r in horizontal position The oil level must reach the lower edge of the emptying hole Clean and reinstall drain plug 2 and its washer Clean and reinstall filler plug 1 and its washer Before draining o...

Page 56: ...her plug for good functioning 1 Reinstall breather plug 1 and its seal Before carrying out any maintenance or repairs on the machine switch off the tractor engine remove ignition key wait until all mo...

Page 57: ...g hole Top up if necessary Clean and reinstall filler plug 1 and its washer Replace if necessary Before checking that the discs rotate freely by hand If it is found that the transmission case is very...

Page 58: ...l 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 Replace if necessary Check angle gearbox oil level The oil level m...

Page 59: ...configuration possibilities I For machines up to serial number K0211 Coupling device a II For machines up to serial number K0211 Coupling device b or For machines with serial number as from K0212 Coup...

Page 60: ...ses 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 dis...

Page 61: ...the beginning of each season The fixing bolts should be changed in the following cases 2 When there is visible distortion When the locking compound is worn or inoperational When diameter D of the bol...

Page 62: ...8 must exceed 74 mm 2 9 Knife replacement Check the condition of the fixing elements regularly and also the torque of the knife fixing bolt Torque 12 daN m 89 lbf ft See section Spring plate replaceme...

Page 63: ...ecial tool between disc and spring plate Pivot special tool downwards to free spring plate from screw head Make sure that the securing nut and bolt are in good condition and if necessary replace them...

Page 64: ...tion of rotation Pivot special tool downwards to free spring plate from screw head Insert the new knife on the screw head Knife for disk rotating to the left Part no K6801410 Knife for disk rotating t...

Page 65: ...eck 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 After replacing the last kni...

Page 66: ...rs using the box spanner supplied with the machine Remove the disc conical cover Remove the 2 screws 1 and their spring washers Remove the disc 2 When remounting Position their largest diameters at ri...

Page 67: ...disk spring plate Intermediate disk spring plate Remove the disc See section Disc replacement Remove spring plate 1 Refit the disc See section Disc replacement The replacement of the inner disc sprin...

Page 68: ...ough 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 20 mm...

Page 69: ...At the start of each season The fixing bolts should be changed in the following cases 2 When there is visible distortion When the locking compound is worn or inoperational When diameter D of the bolt...

Page 70: ...8 must exceed 60 mm 2 4 Knife replacement Check the condition of the fixing elements regularly and also the torque of the knife fixing bolt Torque 12 daN m 89 lbf ft See section Spring plate replaceme...

Page 71: ...special tool between disc and spring plate Pivot special tool downwards to free spring plate from screw head Make sure that the securing nut and bolt are in good condition and if necessary replace the...

Page 72: ...ew head Insert the new knife on the screw head Knife for disk rotating to the left Part no K6802970 Knife for disk rotating to the right Part no K6802980 Press knife upwards and pull it towards yourse...

Page 73: ...eck 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 After replacing the last kni...

Page 74: ...rs using the box spanner supplied with the machine Remove the disc conical cover Remove the 2 screws 1 and their spring washers Remove the disc 2 When remounting Position their largest diameters at ri...

Page 75: ...move spring plate 1 Refit the disc See section Disc replacement Outer and inner cones Check torque of attachment bolts 1 of outer and inner cone covers 2 and 3 Torque 6 daN m 44 lbf ft Replace any los...

Page 76: ...Inspect and replace worn knives and bolts See section Inspection of knives and securing elements Release belt tension At the start of each season Re read the operators manual Inspect and replace worn...

Page 77: ...to the ground Fit raised skid shoes Bad ground contour adaptation Incorrect main frame setting Adjust main frame height with regards to the ground Excessive ground speed Reduce ground speed Hydraulic...

Page 78: ...ide Incorrect mowing unit positioning with regards to the tractor when placed in working position The tractor valve double acting position has not been used to lower the mowing unit Use the tractor do...

Page 79: ...T kg Tractor unladen weight T1 kg Unladen load on tractor front axle T2 kg Empty load on tractor rear axle t kg Axle loads Tractor machine t1 kg Load on front axle Tractor machine t2 kg Load on rear...

Page 80: ...required minimum front load is reached Indicate front axle calculated load value and the one indicated in the tractor operators manual T1 real M1 x a b T1 x b M2 x c d b 4 Calculation of the total we...

Page 81: ...ual Double value of the authorized capacity per tyre 2 tyres Minimum front rear ballasting kg Total weight kg kg Load on front axle kg kg kg Load on rear axle kg kg kg The minimum ballasting must be m...

Page 82: ...eight M2 and the position of its centre of gravity d Tractor only T1 Load on front axle Tractor only T2 Load on rear axle Tractor only If the data required to calculate the total weight axle loads and...

Page 83: ...Appendix Disc mower GMD800GII FF 81 T Axle loads Tractor only...

Page 84: ...le loads Tractor machine Hopper empty Calculating the rear tool weight M2 M2 T t Calculating the distance d d b x T1 t1 M2 c If the total unit weight exceeds the tractor Gross Combined Weight Rating i...

Page 85: ...Limited warranty Disc mower GMD800GII FF 83 Limited warranty...

Page 86: ...Disc mower 84 GMD800GII FF Limited warranty...

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