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OPERATOR'S MANUAL
KN198KGB D
Disc mower
-FF
GMD800GII
KN198KGB D
- English - 04-2010
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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
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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
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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
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1. Front view
Disc mower
GMD800GII-FF
$Identification of the machine
2. Rear view
4
Identification of the machine
Page 7
3. Model identification plate
Please write below the type and serial number of the
machine. This information is to be indicated to the dealer
for all spare parts orders.
Type: GMD800GII
Disc mower
GMD800GII-FF
Serial no.:
4. Optional equipment
Tick box corresponding to the equipment fitted on your
machine:
Kit no. 1036230: Raised skid shoes 90 mm (3.54’’).
Kit no. 1036340: Side deflector.
Kit no. 1036290: Side deflector with high cone disk.
Kit no. 1026100: Lighting and signalling.
Kit no. 1016440: Lateral signalling equipment.
Kit no. 1066010: 1000 min
-1
drive kit.
Kit no. 56820700: Longer hitc h pins.
Identification of the machine
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$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.
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Safety
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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
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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.
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Safety
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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
Disc mower
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
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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)
Disc mower
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).
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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.
Disc mower
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
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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
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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
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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
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Safety
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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
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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.
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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
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GMD800GII-FF
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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.
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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.
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Safety
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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
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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
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$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
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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
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Machine specifications
Page 27
$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
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2. Coupling and uncoupling
The machine adapts to tractors fitted with a 3 point
linkage category 2.
Description of coupling elements
- A PTO shaft 1 3/8’’ - 6 splines.
- A check chain.
- A release cord.
- 1 hydraulic hose controlling the machine
transport/work position cylinder.
Disc mower
GMD800GII-FF
Preparing the tractor
Check that the tractor's authorized gross
weight as well as its lift capacity and
maximum weight per axle are not exceeded.
The front axle load (1) must never, under any
circumstances, be less than 20% of the
tractor's unladen weight. Add ballast weights
to the front in order to preserve the steering
and braking efficiency.
-
The tractor must be fitted with lower link
stabilizers.
-
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.
26
Putting into service
Page 29
Hitch pin parallelism
Adjust tractor lift rods so that hitch pins are parallel to th e
ground.
Disc mower
GMD800GII-FF
Lateral adjustment of the lower links
- Balance the play on either sides of the lift linkage and
lock lower link stabilizers.
Putting into service
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Preparing the machine
Positioning of lower links
- Measure dimension E.
- Adjust tractor lower link stabilizers to measure E =
50 mm (2").
Linkage adjustment
Disc mower
GMD800GII-FF
E
- 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 F = 10 mm (0.4").
- Tighten 4 hitch pin screws (1).
• 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).
A
F
X
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Putting into service
Page 31
If measure A is comprised between 2.10 m (6’11")
and 2.25 m (7’04"):
- Place lower links in position b:
Adjust machine lower hitch pin position:
- Loosen the 8 screws (3).
- Centre hitch pin (1) with regards to the mounting plate.
- Tighten 4 hitch pin screws (1).
• 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 links in position c:
Adjust machine lower hitch pin position:
- Loosen the 8 screws (3).
- Position hitch pin (2) at measure G = 10 mm (0.4").
- Tighten 4 hitch pin screws (2).
• Torque : 12 daN m (89 lbf ft).
- Position hitch pin (1) at measure (X = 825 mm (2’8").
- Tighten 4 hitch pin screws (1).
Torque : 12 daN m (89 lbf ft).
Disc mower
GMD800GII-FF
X
G
X
Putting into service
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Coupling the machine
- Lower the tractor three-point linkage.
- Position ball joints of tractor lower links in line with
machine lower yokes.
- Attach the lower links to the hitch pins.
- Secure each hitch pin with lynch pin.
Disc mower
GMD800GII-FF
- Attach top link (1) in one of the upper holes on the
tractor side.
- Insert and lock top link lynch pin.
- Place release cord handle in the tractor cab.
- Lift machine using tractor hydraulic lift linkage.
- Fold and lock parking latch (1) using spring (2).
30
Putting into service
The parking latch must always be locked for
work and transport.
Page 33
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 and check chains’’.
Disc mower
GMD800GII-FF
Putting into service
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Primary PTO shaft
Make sure that the PTO shaft is correctly
adjusted, to avoid premature wear and tear.
The tractor PTO stub must rotate at a speed of 540 min-1.
Separate the two half PTO shafts and connect them to
the machine's input shaft and to the tractor PTO stub.
Check the length of the PTO shaft:
- When the PTO shaft is in its maximum overlap
position (retracted), tubes should not butt against the
yokes. As a safety measure, a clearance (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’’).
Disc mower
GMD800GII-FF
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 tran smission tubes
by the same length.
• Bevel and clean the tubes.
• Grease the inside of the outer tube.
Never operate the PTO shaft at an angle X exceeding
30°.
To avoid serious accidents, the PTO drive
shaft guards must be properly in place and
fixed with the chains provided.
32
Putting into service
Page 35
-
On machine side, attach guard chain to the main frame.
Immediately replace any worn or damaged
guard.
Adjusting the machine
Frame height and check chains.
- Tractor fitted with a hydraulic position control function:
• Lower tractor lift linkage in order to engage lift stop
(1) in its housing.
• Respect a lift stop functional play A of 3 mm (0.1’’).
• Note the corresponding lever position in the tractor
cab.
Disc mower
GMD800GII-FF
It is not necessary to use the check chain
supplied with the machine.
Tractor not fitted with a hydraulic position control
function:
• Attach 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 of 3 mm (0.1’’).
The tractor lift linkage is in working position.
The frame height is correct when:
• The cutterbar is resting on the ground.
• The check chain is under tension.
• The lift stop has a functional play of approximately
3 mm (0.1’’) in its housing.
• The 2 hitch pins are parallel to the ground.
Close hook eyelet with roll pin when properly adjusted.
Putting into service
33
Page 36
Uncoupling the machine
For tractors not fitted with a hydraulic
position control function, unhook and attach
check chain to its support.
- Place the cutterbar in horizontal position.
- Release parking lock (1).
- Engage parking latch behind the bevel gearbox
mounting plate (2).
- Lower the tractor three-point linkage to rest the
machine on the ground.
Make sure no foreign material is located on
the bevel gearbox.
Disc mower
GMD800GII-FF
- Uncouple the PTO shaft.
- Place PTO shaft 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 links.
- Lower the tractor three-point linkage.
The machine is uncoupled.
Always park the machine with the cutter bar
in horizontal position.
34
Putting into service
Page 37
$Instructions for transport
Before placing the machine into transport
position:
Wait until the rotating parts have come to a
complete stop.
Check that nobody is locate d in the machine
pivoting area. If there is someone, make su re
the person moves away.
1. Putting the machine into transport position
Disc mower
GMD800GII-FF
When optional equipment is used, follow specific
procedures mentioned in the related section:
- Lighting and signalling.
- Lateral signalling equipment.
From the working position:
- Unlock and lift front guard using 18mm box spanner
supplied with the machine.
- The guard locks automatically.
- Pull release cord until lift stop (1) is free.
- Lift the machine using the tractor's lift linkage.
- Activate the transport/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 transport position.
Instructions for transport
35
Page 38
The machine is in transport position.
Never engage the tractor PTO drive when the
machine is in transport position.
2. Conformity with the road regulations
Disc mower
GMD800GII-FF
Before driving the machine on public roads,
ensure that the machine complies with
current highway code regulations.
Check that the retroreflective signalling equipment is
clean before going on public roads.
Replace worn or damaged reflectors.
Make sure the release cord cannot be
operated inadvertently.
Make sure that transport lock (1) is fully
engaged.
36
Instructions for transport
Page 39
$Instructions for work
Before placing the machine in working
position:
- Check that nobody is within the machine
pivoting area.
- If there is someone, make sure the
person moves away.
1. Putting the machine into work position
Disc mower
GMD800GII-FF
When optional equipment is used, follow specific
procedures mentioned in the related section:
- Lighting and signalling.
- Lateral signalling equipment.
From the transport position:
- Fully lift tractor lift linkage.
- Operate transport/work position cylinder to relieve
pressure on the transport lock.
- Pull the release cord 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.
Instructions for work
37
Page 40
- Shift the 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
cylinder to place the machine in headland
turn position.
Disc mower
GMD800GII-FF
38
Instructions for work
Page 41
2. Adjustments in working position
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.
Cutting height
The desired cutting height is obtained directly by
adjusting the top link length. The height can be adjusted
from 30 to 50 mm (1.1" - 1.9").
To obtain a different cutting height:
- Place the machine in working position.
- Lower the machine on the ground to remove weight
from the top link.
- Modify the top link length to alter the machine tilt
angle.
- Check cutting height.
Disc mower
GMD800GII-FF
The maximum cutting height (L1 = 50 mm (1.9’’))
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.
-
Instructions for work
39
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’).
Disc mower
GMD800GII-FF
Check that there is a minimum clearance (J)
of 15 mm (0.59’’) between the cone rib and
the swath wheel.
40
Instructions for work
Page 43
Compensating spring tension
The mowing unit is suspensed by means of
compensating spring (1).
In difficult working conditions, the compensating spring
adjustment can be modified.
- Place the machine in working position.
- Lift mowing unit to release tension on the spring.
- Loosen counter nut (2).
- Rotate spring (1) to modify the mowing unit
suspension:
• Reduce measure (X) to increase the suspension.
• Increase measure (X) to reduce suspension.
Disc mower
GMD800GII-FF
The measure (X) is factory set at 90 mm (3.5").
- Tighten counter nut (2).
3. Machine use
Before mowing and to reduce risks of
projections, lower the front guard.
Keep all persons and animals away from the
machine danger zone.
Never lean or step on the protection cover.
At work, the tractor hydraulic valve must
always be in floating position to ensure good
ground contour adaptation.
Before the machine engages the crop:
- Engage the tractor PTO and slowly increase the
speed up to 540 min
-1
.
Instructions for work
41
Page 44
Groundspeed
Adapt the forward speed to the working
conditions.
Headland turn maneuvers
Operate the cutterbar using the "pivot into
transport/work" position cylinder.
- Activate the transport/work cylinder control valve in
the "pivot into transport" position. The cylinder lock (1)
bottoms.
Disc mower
GMD800GII-FF
The lift linkage clears simultaneously the
main frame and cutter bar off the ground.
42
Instructions for work
Page 45
Machine safety
When hitting an obstacle:
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.
The break-away latch allows the cutter bar to pivot to the
rear when hitting an obstacle.
In case an obstacle has been struck, check
that the mowing unit has not been damaged.
Disc mower
GMD800GII-FF
The safety breakback is reset by reversing (a).
Instructions for work
43
Page 46
If the break-away latch r eleases too easily after reset,
tighten nut (1) to increase spring washer compression
slightly.
Respect spring washer layout.
Basic adjustment:
L= 95 mm (3.7’’)
For normal functioning of the break-away latch,
measure L must never be below 91 mm (3.60").
In case of clogging:
Before carrying out any maintenance or
repairs on the machine, switch off the trac tor
engine, remove ignition key, wait until all
moving parts have come to a standstill and
apply park brake.
Disc mower
GMD800GII-FF
- Lift and lock front guard.
- Remove foreign body.
- Check that the mowing unit has not been damaged.
- Check rotating components for damage.
- Lower and lock front guard.
44
Instructions for work
Page 47
$Optional equipment
1. Raised skid shoes
Kit no. 1036230
The raised skid shoes enable mowing higher, between
35 and 90 mm (1.4’’ - 3.5’’).
Replace the end disc skids by the 2 raised skid shoes.
The use of raised skid shoes is also
recommended on sticky grounds.
Disc mower
GMD800GII-FF
2. Side deflector
Kit no. 1036340
The side deflectors enables mowing dense or down
crops with long stems.
Fit side deflector on the outer side plates o f the cutterbar
stiffener.
Optional equipment
45
Page 48
3. Side deflector with high cone disk
Kit no. 1036290
Large cone discs allow mowing dense or down crops
with long stems.
The side deflector prevents crop from wrapping around
the outer large cone disk when mowing in dense or down
crops with long stems.
Disc mower
GMD800GII-FF
4. Lighting and signalling
Kit no. 1026100
The machine can be fitted with specific signalling lights
to comply with the road regulations.
Electrical connection
Connect machine 7-pin plug on the tractor 7-pin socket.
After making the connections, check that there is no risk
of the cables being caught during operation.
46
Optional equipment
Page 49
Instructions for transport
- Position rear signalling device.
- Connect signalling device wiring harness.
Disc mower
GMD800GII-FF
Instructions for work
- Disconnect signalling device wiring harness.
- Position rear signalling device.
5. Lateral signalling equipment
Kit no. 1016440
The machine can be fitted with specific signalling lights
to comply with the road regulations.
Optional equipment
47
Page 50
1 on each machine side.
Disc mower
GMD800GII-FF
1 in combination with signalling panel.
Lighting and signalling:
Kit no. 1026100
6. 1000 min-1 drive kit
Kit no. 1066010
Belt and pulley assembly for tractors with a pto speed of
1000 min
-1
.
48
Optional equipment
Page 51
7. Longer hitch pins
Kit no. 56820700
The longer hitch pin enables offsetting the machine by
200 mm (7.9’’).
Linkage adjustment
Disc mower
GMD800GII-FF
- 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 hitch pin screws (2).
• Torque : 12 daN m (89 lbf ft).
- Position left longer hitch pin (1) at a distance of X =
825 mm (2’8").
- Tighten 4 hitch pin screws (1).
• Torque : 12 daN m (89 lbf ft).
A
Optional equipment
49
Page 52
$Maintenance and storage
Before carrying out any maintenance or
repairs on the machine, switch off the trac tor
engine, remove ignition key, wait until all
moving parts have come to a standstill and
apply park brake.
Disc mower
GMD800GII-FF
1. Frequency chart
Maintenance intervals are indicated for
normal conditions of use.
Cutterbar draining and refilling
Lubricate moving parts and
articulations
Changing angle gearbox oil
After the first 10
hours of use
33
33
Every 50 hours
3
Every 200 hours
or at the end of
the season
50
Maintenance and storage
Page 53
2. Lubrication
Lubricate with SHELL multi-purpose grease
grade NLGI 2.
PTO shaft
Primary PTO shaft
- Every 8 hours:
• universal joints (1).
- Every 20 hours:
• transmission tube (2).
- Every 40 hours:
• guide rings (3).
Disc mower
GMD800GII-FF
Place the machine in working position.
Stop the tractor engine and remove ignition
key.
Maintenance and storage
51
Page 54
Cutterbar draining and refilling.
Before draining oil, operate the machine for a
few minutes so that the oil warms up.
The cutterbar is lubricated with 2.25 L (0.5 9 US gal) of SHELL SPIRAX A extreme-pressure gear oil
with viscosity grade SAE 80W90 and API grade GL5.
When draining and refilling, it is recommended to use either a mineral base oil with viscosity grade
SAE 80W90 and API grade GL5, or a synthetic base oil, type PAO (Poly-Alpha-Olefin s) with a viscosity
grade equivalent to SAE 80W90.
Never use an oil of viscosity SAE 90 in the
cutterbar.
From the transport position:
Disc mower
GMD800GII-FF
For safety reasons, hook check chain as high as
possible.
- Place a container of sufficient capacity under drain
plug.
- Remove filler plug (1) and its washer.
- Unscrew drain plug (2) and its seal.
- Allow oil to drain completely.
- Wait for dripping to stop.
- Clean and reinstall drain plug (2) and its washer.
Replace if necessary.
- Pour the correct oil quantity and quality through the
opening of the filler plug.
- Clean and reinstall filler plug (1) and its washer.
Replace if necessary.
- Check angle gearbox oil level:
• The oil level must reach the lower edge of the
emptying hole.
- Clean and reinstall drain plug (2) and its washe r .
- Clean and reinstall filler plug (1) and its washer.
52
Maintenance and storage
Page 55
Changing angle gearbox oil.
Before draining oil, operate the machine for a
few minutes so that the oil warms up.
The angle gearbox is lubricated with 0.45 L (0.12 US gal) of SHELL SPIRAX A extre me-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 base oil with viscosity grade
SAE 80W90 and API grade GL5, or a synthetic base oil, type PAO (Poly-Alpha-Olefins) with a viscosity
grade equivalent to SAE 80W90.
From the transport position:
- Remove filler plug (1) and its washer.
- Place a container of sufficient capacity under drain
plug.
- Remove drain plug (2) and its washer.
- Allow oil to drain completely.
- Wait for dripping to stop.
- Place the cutterbar in horizontal position.
- Pour the correct oil quantity and quality through the
opening of the filler plug (1).
Disc mower
GMD800GII-FF
- Check angle gearbox oil level:
- Place the cutterbar 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.
Maintenance and storage
53
Page 56
3. Maintenance
Before carrying out any maintenance or
repairs on the machine, switch off the trac tor
engine, remove ignition key, wait until all
moving parts have come to a standstill and
apply park brake.
Belt tension
Regularly check belt tension and in particular
during the first hours of use.
Never replace belts individually.
Replace belts in full sets.
Disc mower
GMD800GII-FF
Adjusting the tension:
- Tighten screw (1) using the 18mm box spanner
supplied with the machine.
- Spacer tube (2) must be in contact with main frame (3)
and washer (4).
During the initial assembly or when installing
a new set of belts, give screw (1) 2 additional
turns to compensate for the inital stretch of a
new set of belts.
Breather plug checking and cleaning
From the working position:
Remove breather plug (1) and its seal.
Clean and check breather plug for good functioning (1).
Reinstall breather plug (1) and its seal.
54
Maintenance and storage
Page 57
Checking cutterbar oil level
Regularly check the cutterbar oil level:
• Place cutter bar in vertical position.
• Remove filler plug (1) and its washer.
• Check the oil level.
• Top up if necessary.
• Clean and reinstall filler plug (1) and its
washer. Replace if necessary.
Disc mower
GMD800GII-FF
• The oil must reach the lower edge of the filling hole.
• Top up if necessary.
• Clean and reinstall filler plug (1) and its
washer. Replace if necessary.
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
respected.
- Discs can be rotated freely by hand when
the machine is hot.
Before checking that the discs rotate freely by hand:
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.
Maintenance and storage
55
Page 58
Check angle gearbox oil level
Regularly check the oil level:
• Place the cutterbar in horizontal 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.
Disc mower
GMD800GII-FF
Replace if necessary.
- Check angle gearbox oil level:
• The oil level must reach the lower edge of the
emptying hole.
- Clean and reinstall drain plug (1) and its washe r .
- Clean and reinstall filler plug (2) and its washer.
56
Maintenance and storage
Page 59
Inspection of knives and securing
elements
Immediately replace worn or damaged parts with genuine KUHN parts.
The following procedures take into account the 2 machine configuration possibilities:
Disc mower
GMD800GII-FF
I ) For machines up to serial number K0211
II ) For machines up to serial number K0211
or For machines with serial number as from K0212
Coupling device (a) Coupling device (b)
New spring plate New spring plate
+ Coupling device (a).
+ Coupling device (b)
Never mount a knife in configuration (b) with a spring plate in configuration (a).
Never fit a bolt in configuration (a) with spring plate in configuration (b)
Maintenance and storage
57
Page 60
I ) For machines up to serial number K0211 + Coupling device (a).
Knives
Inspect systematically all knives before the machine is
operated to:
- guarantee the cutting quality.
- guarantee safety in use.
- Prevent cutterbar damage risks.
Replace knives in the following 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 20 mm (0.78’’).
Disc mower
GMD800GII-FF
The hole L for the securing bolt must not become oval by
more than 22 mm (0.86’’).
Always replace both knives per disc to avoid creating an
out-of-balance force.
58
Maintenance and storage
Page 61
Fixing elements
Check the fixing elements:
- After hitting an obstacle.
- When replacing knives.
- At the beginning of each season.
Disc mower
GMD800GII-FF
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’’).
Maintenance and storage
59
Page 62
Replace nuts in the following cases (1):
- When nut wear reaches a = 5 mm (0.2’’).
Check the condition of the fixing elements
regularly and also the torque of the knife-fix ing
bolt:
- Torque: 12 daN m (89 lbf ft).
Replace spring plate in the following cases (3):
- When there is visible distortion.
- When you have noticed important wear on a spring
plate:
• Width B of a spring plate, measured at A =
20 mm (0.8’’), must exceed 74 mm (2.9’’).
Disc mower
GMD800GII-FF
See section: ’’Spring plate replacement’’.
Knife replacement
Before carrying out any maintenance or
repairs on the machine, switch off the trac tor
engine, remove ignition key, wait until all
moving parts have come to a standstill and
apply park brake.
Replace immediately all worn or distorted
knives.
Never straighten a bent knife.
Always replace both knives per disc.
60
Maintenance and storage
Page 63
Parking
- Clean the top side of the disk guard.
- Clean cavities between disc and spring plate.
- Fully insert special tool between disc and spring plate.
Disc mower
GMD800GII-FF
- 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:
• Torque: 12 daN m (89 lbf ft).
Bolt: Part no. K6801010 (2).
Nut: Part no. 80201262 (1).
Dull knives require more horse power and have a
negative effect on the cut quality.
Maintenance and storage
61
Page 64
Fitting
Knives can be turned over on the same disc to use the
other cutting edge or replaced. On each knife , an arrow
indicates the disc's direction of rotation.
Knife for disk rotating to the left: Part
no. K6801410
Knife for disk rotating to the right: Part
no. K6801420
- Pivot special tool downwards to free spring plate from
screw head.
- Insert the new knife on the screw head.
Disc mower
GMD800GII-FF
Press knife upwards and pull it towards
yourself before releasing the special tool.
- (a), (b), (c)
Checking the full locking and free rotation of
the knife on the screw head.
62
Maintenance and storage
Page 65
- Check 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.
Disc mower
GMD800GII-FF
After replacing the last knife, check that the
tool has been removed and put away.
Maintenance and storage
63
Page 66
Disc replacement
Inner disc:
The replacement of the inner disk must be
carried out by your Kuhn authorized dealer.
Intermediate disc:
- Place a wooden wedge (2) between two discs to stop
them from moving.
- Remove 2 bolts (1) and their spring washers using the
box spanner supplied with the machine.
- Remove the disc conical cover.
Disc mower
GMD800GII-FF
- Remove the 2 screws (1) and their spring washers.
- Remove the disc (2).
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).
64
Maintenance and storage
Page 67
Spring plate replacement
The inner disk spring plate:
The replacement of the inner disc spring
plate must be carried out by a Kuhn
authorized dealer.
Intermediate disk spring plate:
- Remove the disc.
• See section: ’’Disc replacement’’.
Disc mower
GMD800GII-FF
- Remove spring plate (1).
Spring plate Part no. K6801090.
- Refit the disc.
• See section: ’’Disc replacement’’.
Maintenance and storage
65
Page 68
II ) For machines up to serial number K0211 + Coupling device (b)
or For machines with serial number as from K0212.
Knives
Inspect systematically all knives before the machine is
operated to:
- guarantee the cutting quality.
- guarantee safety in use.
- Prevent cutterbar damage risks.
Replace knives in the following 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 20 mm (0.78’’).
Disc mower
GMD800GII-FF
The hole L for the securing bolt must not become oval by
more than 22 mm (0.86’’).
Always replace both knives per disc to avoid creating an
out-of-balance force.
66
Maintenance and storage
Page 69
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’’).
Disc mower
GMD800GII-FF
See section: ’’Disc replacement’’.
The radial play between a worn bolt and a new
knife must not exceed d = 10 mm (0.4’’).
Maintenance and storage
67
Page 70
Replace nuts in the following cases (1):
- When nut wear reaches a = 5 mm (0.2’’).
Check the condition of the fixing elements
regularly and also the torque of the knife-fix ing
bolt:
- Torque: 12 daN m (89 lbf ft).
Replace spring plate in the following cases (3):
- When there is visible distortion.
- When you have noticed important wear on a spring
plate:
• Width B of a spring plate, measured at A =
20 mm (0.8’’), must exceed 60 mm (2.4’’).
Disc mower
GMD800GII-FF
See section: ’’Spring plate replacement’’.
Knife replacement
Before carrying out any maintenance or
repairs on the machine, switch off the trac tor
engine, remove ignition key, wait until all
moving parts have come to a standstill and
apply park brake.
Replace immediately all worn or distorted
knives.
Never straighten a bent knife.
Always replace both knives per disc.
68
Maintenance and storage
Page 71
Parking
- Clean the top side of the disk guard.
- Clean cavities between disc and spring plate.
- Fully insert special tool between disc and spring plate.
Disc mower
GMD800GII-FF
- 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.
• Torque: 12 daN m (89 lbf ft).
Bolt: Part no. K6801011.
Nut: Part no. 80201262.
Dull knives require more horse power and have a
negative effect on the cut quality.
Maintenance and storage
69
Page 72
Fitting
Knife for disk rotating to the left:
- Part no. K6802970
Knife for disk rotating to the right:
- Part no. K6802980
- Pivot special tool downwards to free spring plate from
screw head.
- Insert the new knife on the screw head.
Disc mower
GMD800GII-FF
Press knife upwards and pull it towards
yourself before releasing the special tool.
- (a), (b), (c)
Checking the full locking and free rotation of
the knife on the screw head.
70
Maintenance and storage
Page 73
- Check 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.
Disc mower
GMD800GII-FF
After replacing the last knife, check that the
tool has been removed and put away.
Maintenance and storage
71
Page 74
Disc replacement
Inner disc:
The replacement of the inner disk must be
carried out by your Kuhn authorized dealer.
Intermediate disc:
- Place a wooden wedge (2) between two discs to stop
them from moving.
- Remove 2 bolts (1) and their spring washers using the
box spanner supplied with the machine.
- Remove the disc conical cover.
Disc mower
GMD800GII-FF
- Remove the 2 screws (1) and their spring washers.
- Remove the disc (2).
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).
72
Maintenance and storage
Page 75
Spring plate replacement
The inner disk spring plate:
The replacement of the inner disc spring
plate must be carried out by a Kuhn
authorized dealer.
Intermediate disk spring plate:
- Remove the disc:
• See section: ’’Disc replacement’’.
- Remove spring plate (1).
Disc mower
GMD800GII-FF
Spring plate Part no. K6803410.
- 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 lost or damaged cover.
- (2) Part no. 56803420.
- (3) Part no. 56803400.
Maintenance and storage
73
Page 76
4. Storage
At the end of each season
- Clean the machine thoroughly.
- Drain gearbox and cutterbar and refill with new oil.
- Touch up any areas of damaged paintwork.
- Store machine with the cutter bar in horizontal position
in a sheltered dry place.
- 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 knives and bolts (See
section "Inspection of knives and securing elements").
- Check that all nuts and bolts are sufficiently tightened.
- Check belt condition. Replace them if necessary.
- Check belt tension. Retension if necessary
- Make sure that all protection devices are in place and
in good condition.
Disc mower
GMD800GII-FF
74
Maintenance and storage
Page 77
$Trouble shooting guide
-
Problem Cause Remedy
Dull or broken knives. Replace knives.
Make sure the arrow on the
Uneven stubble.
Soil build up in front of the
cutterbar.
Bad ground contour
adaptation.
Stubble too long.
Too frequent safety breakback
release.
Knives not installed correctly.
Insufficient disk speed. Check belt tension.
Too low PTO speed
(rotational frequency).
Cutter bar pitch angle too high. Reduce angle.
Too much cutterbar down
pressure.
Very wet working conditions.
Incorrect main frame setting.
Excessive ground speed. Reduce ground speed.
Hydraulic cylinder blocked.
Incorrect compensating spring
adjustment.
Cutter bar pivot bushes are
worn or seized.
Incorrect cutter bar pitch angle.
Machine too light.
Insufficient spring washer
compression.
knife upper face is pointing in
the disc's direction of rotation.
Increase speed to 540 min
Adjust compensating spring
tension.
Adjust main frame height with
regards to the ground.
Fit raised skid shoes.
Adjust main frame height with
regards to the ground.
Set hydraulic valve in floating
position.
Adjust compensating spring
tension.
Check condition of pivot
bushes. Replace if necessary.
Modify pitch angle using top
link.
Adjust compensating spring
tension.
Check frame position.
Increase spring washer
compression.
Disc mower
GMD800GII-FF
-1
.
Interference between tractor
and front guard.
Incorrect cam adjustment. Adjust machine pivot moment.
Trouble shooting guide
75
Page 78
Disc mower
GMD800GII-FF
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 double acting
position to lower the mowing
unit.
76
Trouble shooting guide
Page 79
$Appendix
1. Calculating the load on an axle
When coupling a tool to the front and rear 3-point lift linkage, the maximum authorized payload must
not be exceeded.
The load on the tractor front axle must always represent 20 % of the tractor unladen weight.
Prior to use, check that these conditions are satisfied by making this calculation or by weighing the
tractor-machine unit
Define the total weight, axle loads, tyre
capacity and minimum additional mass:
Disc mower
GMD800GII-FF
The following values are required for the calculation:
Description Units Description
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 axle (Tractor + machine)
M1 kg Total weight of front tool or front ballast
M2 kg Total weight of rear tool or rear ballast
am
b m Distance between the tractor axles
cm
d m
Distance between the tools' centre of gravity or the front ballast and
the front axle centre
Distance between the rear axle center and the center of the lower link
ball joints
Distance between the centre of the lower link ball joints and the centre
of gravity of the rear tool or rear ballast
Obtained
by
Refer to the tractor operators' manual Refer to the machine price-list or operators' manual
Dimensions Measure on scale
Appendix
77
Page 80
Rear tool or front-rear combination:
Disc mower
GMD800GII-FF
1) Calculation of the minimum front ballast weight M1
minimum
M2 x (c+d) - T1 x b + 0.2 x T x b
M1
minimum
=
a+b
Write the minimal additional weight in the chart.
Front tool:
2) Calculation of the minimum rear ballast weight M2
minimum
M1 x a - T2 x b + 0.45 x T x b
M2
minimum
=
b+c+d
Write the minimal additional weight in the chart.
3) Calculation of the actual load on the front ax le T1
If the front tool (M1) is lighter than the minimum load required at the front (minimum), increase tool weight until the required minimum
front load is reached
real
M1 x (a+b) + T1 x b - M2 x (c+d)
T1
=
real
b
Indicate front axle calculated load value and the one indicated in the tractor op erators' manual.
4) Calculation of the total weight M
If the rear tool (M2) is lighter than the minimum load required at the rear(minimum), increase tool weight until the required minimum
rear load is reached
real
M
= M1 + T + M2
real
Indicate calculated total load value and the o ne author ized as indicated in the tractor oper ator's manual.
5) Calculation of the actual rear axle load T2
T2
= M
real
real
real
- T1
real
Indicate rear axle calculated load value and the one indicated in the tractor operator's manual.
6) Tyre carrying capacity
Indicate double (2 tyres) the authorized load value (see tyre manufacturer indications).
78
Appendix
Page 81
Table:
Disc mower
GMD800GII-FF
Actual value obtained
by calculation
Minimum front/rear
ballasting
Total weight kg ≤ kg
Load on front axle kg ≤ kg ≤ kg
Load on rear axle kg ≤ kg ≤ kg
The minimum ballasting must be made by fitting a tool or an additional mass to the
tractor.
The values obtained must be below or equal the authorized values.
kg
Value authorized
according to
operator's manual
Double value of the
authorized capacity
per tyre (2 tyres)
Appendix
79
Page 82
Determining the machine weight (M2) and
the position of its centre of gravity (d)
If the data required to calculate the total
weight, axle loads and minimum ballasting
are not supplied, use the following method.
Tractor only:
Disc mower
GMD800GII-FF
- T1: Load on front axle.
• Tractor only.
- T2: Load on rear axle.
• Tractor only.
80
Appendix
Page 83
- T: Axle loads.
•Tractor only.
Disc mower
GMD800GII-FF
Appendix
81
Page 84
Disc mower
GMD800GII-FF
Rear tool or front-rear combination:
If the total unit weight exceeds the tractor Gross Combined Weight Rating in accordance with th e
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 ta nks.
- Measure dimension (b).
- Measure dimension (c).
- t1: Load on front axle.
• Tractor + machine.
• Hopper empty.
- t: Axle 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
82
Appendix
Page 85
$Limited warranty
Disc mower
GMD800GII-FF
Limited warranty
83
Page 86
Disc mower
GMD800GII-FF
84
Limited warranty
Page 87
Page 88
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