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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 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 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’’).

Содержание GMD800GII-FF

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

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

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

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