KUHN GMD800GII-FF Operator's Manual
OPERATOR'S MANUAL
KN198KGB D
Disc mower
-FF
GMD800GII
KN198KGB D
- English - 04-2010
Disc mower
GMD800GII-FF
$Dear Owner
In buying a Kuhn machine you have chosen wisely. Into it have gone years of thought, research and
improvement. You will find, as have thousands of owners all over the world, that you have the best that
engineering skill and actual field testing can produce. You have purchased a dependable machine, but only
through proper care and operation can you expect to receive the performance and long service built into it.
This manual contains all the necessary information for you to receive full efficiency from your machine. The
performance you get from this machine is largely dependent on how well you read and understand th is manual
and apply this knowledge. Please DO NOT ASSUME YOU KNOW HOW TO 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 complete line of genuine KUHN service parts. These parts ar e manufactured and
carefully inspected in the same factory that builds the machine to assure high quality and accurate fitting of any
necessary replacements.
About improvements
We are continually striving to improve our products. It therefore reserves the right to make improvements or
changes when it becomes practical to do so, without incurring any obligations to make changes or additions to
the equipment sold previously.
Designated use of the machine
The GMD800 GII mower must only be used for the pur pose for which it was manufactured: mowing on the
ground of hay fields, grass silage fields and improved past ures for the purp ose of harve sting fodd er fo r feeding
livestock.
Dear Owner
1
Disc mower
GMD800GII-FF
$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 .......................................................17
Road safety equipment and recommendations...........................................................................22
Machine specifications................................................................................................23
Description and glossary...............................................................................................................23
Technical specifications...................... .... ... ... ....................................................... ... ... .... ... ............24
Sound levels ......... ... ... .... ... ... ... .... ................................................... .... ... ... ... ... .... ... .........................24
Putting into service......................................................................................................25
Description of control elements....................................................................................................25
Coupling and uncoupling..............................................................................................................26
Instructions for transport............................................................................................35
2
Putting the machine into transport position................................................................................35
Conformity with the road regulations...........................................................................................36
Contents
Disc mower
GMD800GII-FF
Instructions for work...................................................................................................37
Putting the machine into work position.......................................................................................37
Adjustments in working position..................................................................................................39
Machine use....................................................................................................................................41
Optional equipment.....................................................................................................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 and storage............................................................................................ 50
Frequency chart .............................................................................................................................50
Lubrication............................................................................................ ..........................................51
Maintenance....................................................................................................................................54
Storage............................................................................................................................................74
Trouble shooting guide...............................................................................................75
Appendix ......................................................................................................................77
Calculating the load on an axle.....................................................................................................77
Limited warranty..........................................................................................................83
Contents
3
1. Front view
Disc mower
GMD800GII-FF
$Identification of the machine
2. Rear view
4
Identification of the machine
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.
Type: GMD800GII
Disc mower
GMD800GII-FF
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 deflector.
Kit no. 1036290: Side deflector with high cone disk.
Kit no. 1026100: Lighting and signalling.
Kit no. 1016440: Lateral signalling equipment.
Kit no. 1066010: 1000 min
-1
drive kit.
Kit no. 56820700: Longer hitc h pins.
Identification of the machine
5
$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.
Disc mower
GMD800GII-FF
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.
6
Safety
Disc mower
GMD800GII-FF
2. Safety instructions
Introduction
The machine must only be operated, maintained and repaired by competent persons who are familiar with
machines' specifications and operation and aware of safety regulations fo r 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 le gislation concerning accident prevention, wo rk safety
and public traffic circulation.
Designated use of the machine also means following operation, maintenance and repair recommendations
given by the manufacturer, and using only genuine spare parts, equipment a nd acce sso ries, as r ecom mended
by the manufacturer.
The manufacturer is not held liable for any damage resulting from machine applications other than those
specified by the manufacturer. Any use other than the designated operation is at the risk and responsibility of
the operator.
The manufacturer is not held liable for any damage or accident re sulting from machine modifications carried out
by the operator himself or by a third party without previous written agreement from the manufacturer.
Read and follow the safety instructions
Before using the machine, carefully read all the safety
instructions in this manual and the warnings placed on
the machine.
Before starting work, the operator must be familiar with
all machine controls, handling devices and their
functions. It is too late to learn once work has been
started!
Never let anyone operate the machine who is not traine d
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
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 a complete stop
and apply park brake.
Safety
7
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.).
Ensure that all operating controls (ropes, cables, rods,
etc) are placed so as they cannot be operated
unintentionally and cause damage or injury.
Before operating the machine, check tightness of nuts
and bolts, particularly on fixing elements (tines, forks,
blades, knives, etc). Retighten if necessary.
Before operating the machine, ensure that all the safety
guards are firmly in place and in good condition.
Immediately replace any worn or damaged guard.
Disc mower
GMD800GII-FF
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 ground conditions as
well as to roads and paths. Always avoid abrupt change s
of direction.
Be particularly cautious when turning corners, paying
attention to machine 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 the machine when
working or in transport is strictly forbidden.
8
Safety
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.
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
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GMD800GII-FF
Before transporting the machine on public road s, ensure
that all 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.
Always obey current regulations for driving
on roads.
Gross weight and weight per axle
The drawings are not legally binding, their only aim is to illustrate the method to use.
Prior to driving on public roads, check t hat criteria are met t o be in conformity with the count rie's
regulations:
- When coupling a tool to the front and rear 3-point lift linkage, the maximum authorized
payload must not be exceeded.
- When coupling tools to the front and rear 3-point lift linkages, the maximum load on each
axle's tires must not be exceeded.
- The load on the tractor front axle must always repr esent 20 % of the tr actor unladen we ight.
Safety
9
For machines with hoppers or tanks:
- If the total unit weight exceeds the tractor Gross Combined Weight Rating in accordance
with the countrie's legislation, empty the hopper to travel on public roads.
- In any case, we recommend to travel on public roads with empty hoppers and tanks.
Description of symbols
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 rear axle
t kg Axle loads (Tractor + machine)
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GMD800GII-FF
t1 kg Load on front axle (Tractor + machine)
t2 kg Load on rear axle (Tractor + machine)
t1 max kg Maximum load authorized on the tractor front axle according to the tires
t2 max kg Maximum load authorized on the tractor rear axle according to the tires
M1 kg Total weight of front tool or front ballast
Stage 1:
To measure:
- Tractor tare (T).
10
Safety
Stage 2:
- Couple the machine to the tractor.
To measure:
- Load on front axle (t1):
• Tractor + machine (transport position).
To do:
- If the front axle load (t1) is below 20% of the tractor
tare (T), add ballast weights (M1) to exceed the
minimum load on the front axle.
Example:
• (T) = 7500 kg (16535 lb)
• The front axle load must be of minimum 1500 kg
(3300 lb).(20% of T)
• (t1) = 700 kg (1545 lb).
• 700 kg (1545 lb) < 1500 kg (3300 lb).
• Add ballast weights until the minimum front axle
load is exceeded.
• Repeat checking procedure.
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GMD800GII-FF
Stage 3:
To measure:
- Total weight (t):
• Tractor + machine (transport position).
• Ballast weights.
Checking:
- To go to the next stage:
• Check in the tractor's operator's manual that the
value measured is below the tractor's Gross
Combined Weight Rating.
To do:
- If t < PTAC go to the next stage.
- If the total unit weight exceeds the tractor Gross
Combined Weight Rating in accordance with the
countrie's legislation, empty the hopper to travel on
public roads.
Example:
• (t) = 10000 kg (24250 lb)
• PTAC = 13000 kg .
• t < PTAC : Go to the next stage.
Safety
11
Stage 4:
To measure:
- Load on rear axle (t2):
• Tractor + machine (transport position).
• Ballast weights.
Checking:
- Check in the tractor's operator's manual that the value
measured is below the maximum 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 the tractor's operator's manual that the
value measured is below the maximum allowed
tractor rear axle load.
• Check that tyre and rim specifiations are in
conformity with the requirements of the tractor
manufacturer.
Disc mower
GMD800GII-FF
12
Safety
Maximum speed
Always keep to the legal speed limit for driving a tractormachine assembly on public roads.
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.
Never stand between the tractor and the machine when
operating the three point linkage.
Do not stand between the tractor and the machine
without ensuring that the parking brake is applied.
Disc mower
GMD800GII-FF
Hydraulic circuit
Caution! The hydraulic circuit is under high pressure.
Maximum pressure at work: 200 bar (2900 psi).
Before connecting hoses to the tractor hydraulics,
ensure that tractor and machine circuits are not under
pressure. Before disconnecting a hose, depressurize the
hydraulic circuit.
To avoid making incorrect connectio ns, mark hydraulic
couplers and corresponding hoses with colors.
WARNING! Functions could be reversed (for example:
lift/lower) and cause accidents.
Regularly check the hydraulic hoses. In case of normal
wear, replace the hydraulic hoses every 5 years.
Damaged or worn hoses must immediately be r eplaced.
When replacing the hydraulic hoses, only use hoses with
the specification recommended by the manufacturer of
the machine.
To locate a leak, use appropriate means. Protect body
and hands from liquid under pressure.
Any liquid under pressure (particularly oil from
hydraulics) can penetrate the skin and cause severe
injury. If injured, see a doctor immediately, there could
be danger of infection.
Before any adjustments, maintenance or repairs are
carried out, lower the machine to the ground,
depressurize the hydraulics, turn off the engine, remove
ignition key and wait until all moving parts have come to
a complete stop.
Safety
13
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.
Make sure that the PTO shaft guards are secured with
the safety chains provided.
Any worn or damaged guards must be replaced
immediately. A worn guard or an unpro tecte d PTO shaft
can cause a serious or even a lethal accident.
Do not wear loose clothing that could be caught in the
rotating PTO shaft.
Before attaching or removing a PTO shaft, or before
doing any work on 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 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) and directions of rotation
are in line with manufacturer's recommendat ion s.
Before engaging the PTO drive, make sure all people
and animals are clear from the machine. Never engage
the PTO drive when the tractor engine is stopped.
When uncoupling the machine, rest the PTO shaft on the
support specially provided, and replace protective cover
on the PTO stub of the tractor.
Read and follow the instructions in the operator's manual
provided with the PTO shaft.
Disc mower
GMD800GII-FF
14
Safety
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. Keep away from these danger zones.
Safety decals
Safety 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.
Disc mower
GMD800GII-FF
Waste disposal
Respect the environment! Never spill pollutants (oil,
grease, filters, etc.) on the ground, never pour them
down the drain and never discard them in any other
place where they could pollute the environment. Never
throw away or burn a tyre. Always take waste to
specialized recycling or waste disposal centers.
Safety
15
Precautions for maintenance and repair
work
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 a complete stop
and apply park brake.
Rest the machine on the gr ound, release the pressure
from the hydraulic circuit and leave the machine to cool
down.
Make sure that the parts of the machine that need to be
lifted for maintenance or repair work are firmly propped
up.
Before any work is done on the electric circuit or before
any electric welding is carried out on the attached
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, 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 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 hardware.
Disc mower
GMD800GII-FF
Projection of stones and foreign objects
For driver safety, always use a tractor equipped with a
cab. Keep the ground to mow free of foreign bodies.
Avoid mowing on stony or rocky grounds. If this is not
possible, take extra safety precautions, such as:
- Fit polycarbonate screens inside the tractor cab's side
and rear windows, or install narrow mesh guards on
their exterior.
- Increase the cutting height to avoid contact with
stones or rocks.
Never start the machine when there are people nearby.
16
Safety
Even when the machine is used in accordance with its
purpose, objects may be projected. Stones and other
foreign objects projected by the movin g parts can tr avel
a considerable distance. Keep all persons and animals
away from the danger zone.
The protection covers help reducing risks of projections.
Therefore, make sure t hat all mower protection devices
are in place and good condition prior to using the
machine.
Regularly check the condition of th e protection covers.
Immediatly replace any worn, damaged or missing
cover.
Precautions for machine use
After each use, check the cutting tools (discs, knives)
and their attachment hardware in accordance with the
instructions given in the present manual. Immediately
replace any worn, damaged or 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 th e 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 reverse.
After disengaging the PTO drive, cuttings tools can
continue rotating for some time. Stay away from the
machine until all moving parts have come to a complete
standstill.
If the machine hits an obstacle, disengage the PTO
drive, stop the tractor engine, remove the ignition key
and wait for all moving parts to come to a complete
standstill. Check the entire machine for any damage
before resuming work.
Disc mower
GMD800GII-FF
3. Location and description of safety decals on the machine
Location of safety decals
Safety
17
Disc mower
GMD800GII-FF
18
Safety
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)
Disc mower
GMD800GII-FF
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 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.
Safety
19
Crushing area (4)
Never operate in an area where there is a crushing risk
before all moving parts have come to a complete stop.
Manoeuvring area (5)
Stay a safe distance from the machine. Crushing hazard.
Disc mower
GMD800GII-FF
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)
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.
20
Safety
Do not step on the machine (8)
Do 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 must always be parked with the cutter bar
in horizontal position (B).
Disc mower
GMD800GII-FF
Safety
21
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:
- 1 red reflector (1).
Always keep to the legal speed limit for driving a tractormachine assembly on public roads. Whatever this
speed, we recommend, for everyone's safety, not to
exceed a speed of 40 km/h (25 mph).
Disc mower
GMD800GII-FF
22
Safety
$Machine specifications
1. Description and glossary
0
Disc mower
GMD800GII-FF
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 : Upper coupling yoke
11 : Safety breakback
Machine specifications
23
2. Technical specifications
Attachment type 3 point, Category 2
Number of discs 8
Working width 3.10 m (10’2’’)
Width in working position 4.98 m (16’4’’)
Height in working position 1.17 m (3’98’’)
Length in working position 1.33 m (4’41’’)
Disc mower
GMD800GII-FF
Width in transport position 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
PTO speed 540 min
Weight 710 kg (1565 lb)
Minimum PTO power requirement 41 kW (55 hp)
3. Sound levels
Sound levels have been measured in accordance with the measuring methods as defined in:
NF EN ISO 4254-1
«Agricultural machinery - Safety - Part 1: General requirements»
Weighted equivalent continuous acoustic pressure level at the driver's seat (closed cabin) L (A) eq:
Tractor only: 76 dB(A)
Tractor + machine: 80.3 dB(A)
-1
-1
24
Machine specifications
$Putting into service
1. Description of control elements
The machine is fitted with a release cord operated from
the tractor cab.
Disc mower
GMD800GII-FF
The machine is supplied with an 18 mm box wrench (1)
to carry out certain adjustment and maintenance tasks.
The machine is supplied with a tool for replacing the
knives.
Putting into service
25
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